Optimization of Direct Laser Deposition Process for Hybrid and Tailored Structures

Additive Manufacturing represents one of the Key Enabling Technologies that allow the manufacturing industry to move forward to its highest evolved form thanks to its high design flexibility, the reduction of scrap materials, and the possibility to tailor the physical and mechanical properties of manufactured parts. More specifically, this work explores the feasibility of producing functionally graded parts by mixing two high-strength steels, i.e. AISI 316L and AISI H13, through Direct Laser Deposition (DLD). This Ph.D. thesis aims to generate new knowledge through an experimental approach that will enrich the landscape of DLD production of Functionally Graded Material (FGM) components. Two different research streams were simultaneously pursued: i) explore the potentialities of DLD in producing tailored parts with customized mechanical properties and chemical composition; ii) the formulation of reliable process guidelines. This work evaluated the optimization and manufacturing process starting from the feedstock analysis to the deposition of two kinds of functionally graded materials. The outcomes are discussed in a critical analysis with the objective of improving the engineered materials scenario for the die and mold industry applications. Finally, the validation of the optimized process parameters was achieved by the production of FGMs benchmarks, which are properly designed and characterized.