| The ability to predict the mechanical properties of engineering materials is crucial to the manufacturing of advanced products. In the aerospace industry, Ti-6Al-4V is commonly used to build structures. Any deviation from the alloy's standard properties can prove detrimental. Thus, the compositional integrity of the material must be controlled.;The ability to directly build and repair large, complicated structures directly from CAD files is highly sought after. Laser Metal Deposition (LMD) technology has the potential to deliver that ability. Before this process can gain widespread acceptance, however, a set of process parameters must be established that yield finished parts of consistent chemical composition. This research aims to establish such a set of parameters.;Design of Experiments was utilized to maximize the information gained while minimizing the number of experimental trials required. A randomized, two-factor experiment was designed, performed, and replicated. Another set of experiments (nearly identical to the first) was then performed. The first set of experiments was completed in an open environment, while the second set was performed in an argon chamber. Energy Dispersive X-Ray Spectroscopy (EDS) was then used to perform a quantitative microanalysis to determine the aluminum level in each sample. Regression analysis was performed on the results to determine the factors of importance. Finally, fit plots and response surface curves were used to determine an optimal parameter set (process window). The process window was established to allow for consistent chemical composition of laser deposited Ti64 parts. |
