Abstract:
In order to investigate the impact of fiber laser process parameters on the geometric dimensions of single-passdeposited layer in laser wire additive manufacturing, a single-factor experimental approach was employed and the single-track deposition experiments were conducted under different laser powers, oscillation amplitudes, scanning speeds and wire feeding speed. The variations in surface morphology and forming dimensions of the deposited layers were analyzed. The results show that as the laser power increases, the melt width of the deposited layer increases while the melt height decreases.Beyond a critical laser power threshold, the transition form from the molten wire to the melting pool changes from liquid bridge to molten drop, which affects the deposition quality. Laser oscillation amplitude predominantly influences the laser spot shape and energy density distribution. As the oscillation amplitude increases, the quality of the deposition layer formation deteriorates. The melt width exhibits a trend of initial enlargement followed by reduction, while the melt height demonstrates the opposite trend. An increase in scanning speed reduces the deposition rate of material per unit time and the thermal input to the substrate, leading to a faster cooling rate of the melt pool and a decrease in both melt width and melt height of the deposited layer. Elevating the wire feed rate enhances the deposition rate of material per unit time, resulting in an increase in both melt width and melt height of the deposition layer. Furthermore, the variation in melt height is more pronounced compared to that of melt width.