Semi-empirical modeling of weaving process for high-quality and property parts in plasma arc directed energy deposition

Abstract Plasma arc directed energy deposition (DED) technology faces challenges, such as low resolution, nonuniform layers, defects, and severe deformation, despite its advantage of rapid, large-scale manufacturing. Although a weaving process offers potential solutions to these issues, its optimization is challenging due to more processing parameters over a stringer process. To address this, we introduce a semi-empirical modeling approach for the weaving process using 316L austenitic stainless steel. This modeling enables the empirical determination of printable region and the numerical alleviation of residual stress and deformation, using multi-heat sources to significantly reduce computing time. Our findings show that a larger weaving process notably decreases bead aspect ratio, dilution, and thermal deformation, thereby reducing uneven beads and layers, compared to the stringer process. Additionally, it enhances heat dissipation and minimizes the heat-affected zone, leading to a remarkable 69.98% increase in elongation while maintaining tensile strength at 486 MPa. This innovative approach offers a practical solution for enhancing the weaving process, overcoming its prevalent challenges to produce high-quality parts with improved properties.