An angle-driven parameter control model for corner paths in the DED-arc process of nickel aluminum bronze alloy

The directed energy deposition-arc (DED-arc) process is gaining popularity for cost-effective production of large parts, especially in the marine industry. However, precise shaping control, especially for parts with sharp corners, has been challenging. Nickel aluminum bronze (NAB) alloy, widely used in the marine field, is an expensive material, making it crucial to improve its forming accuracy. To tackle this challenge, the Angle-Driven Parameter Control Model (APCM) has been introduced. This model is designed to enhance corner paths in the DED-arc process for NAB alloy. By adjusting the travel speed, the APCM aims to reduce height errors at corners. To validate the effectiveness of the APCM, single bead depositions and a multi-layer thin-wall component with seven different angles (10°, 20°, 30°, 45°, 60°, 75°, and 90°) were tested. Results indicate that the APCM has a more significant optimization effect at smaller angles. For angles above 60°, relatively small height deviations can be achieved without parameter control. For the 15-layer thin-wall component, the APCM control reduced the height deviation at the 10° angle from 7.72 to 2.09 mm. Therefore, the proposed APCM is ideal for corner paths in the DED-arc process of NAB alloy.