1、Designation: F3187 16Standard Guide forDirected Energy Deposition of Metals1This standard is issued under the fixed designation F3187; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision. A number in parenthes
2、es indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 Directed Energy Deposition (DED) is used for repair,rapid prototyping and low volume part fabrication. Thisdocument is intended to serve as a guide for de
3、fining thetechnology application space and limits, DED system set-upconsiderations, machine operation, process documentation,work practices, and available system and process monitoringtechnologies.1.2 DED is an additive manufacturing process in whichfocused thermal energy is used to fuse materials b
4、y melting asthey are being deposited.1.3 DED Systems comprise multiple categories of machinesusing laser beam (LB), electron beam (EB), or arc plasmaenergy sources. Feedstock typically comprises either powderor wire. Deposition typically occurs either under inert gas (arcsystems or laser) or in vacu
5、um (EB systems). Although theseare the predominant methods employed in practice, the use ofother energy sources, feedstocks and atmospheres may also fallinto this category.1.4 The values stated in SI units are to be regarded asstandard. All units of measure included in this guide areaccepted for use
6、 with the SI.1.5 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2.
7、 Referenced Documents2.1 The latest version of the specifications referenced belowshould be used, unless specifically referenced otherwise in themain document.2.2 ASTM Standards:2B214 Test Method for Sieve Analysis of Metal PowdersC1145 Terminology of Advanced CeramicsD6128 Test Method for Shear Tes
8、ting of Bulk Solids Usingthe Jenike Shear TesterE11 Specification for Woven Wire Test Sieve Cloth and TestSievesE1316 Terminology for Nondestructive ExaminationsE1515 Test Method for Minimum Explosible Concentrationof Combustible DustsF327 Practice for Sampling Gas Blow Down Systems andComponents fo
9、r Particulate Contamination by AutomaticParticle Monitor MethodF2971 Practice for Reporting Data for Test Specimens Pre-pared by Additive Manufacturing2.3 ISO/ASTM Standards:352900 Additive ManufacturingGeneral PrinciplesTerminology52921 Standard Terminology for Additive ManufacturingCoordinate Syst
10、ems and Test Methodologies2.4 ASQ Standard4ASQ C-1 Specification of General Requirement For A Qual-ity Program2.5 AWS Standards:5A3.0/A3.0M Standard Welding Terms and DefinitionsA5.01/A5.01M Procurement Guidelines for ConsumablesWelding and Allied ProcessesA5.02/A5.02M Specification for Filler Metal
11、StandardSizes Packaging and Physical AttributesA5.14/A5.14M Specification for Nickel and Nickel-AlloyBare Welding Electrodes and RodsA5.16/A5.16M Specification for Titanium and Titanium-Alloy Welding Electrodes and Rods2.6 DIN Standard:DIN 4188 Screening Surfaces; Wire Screens for Test Sieves,Dimens
12、ions1This test method is under the jurisdiction ofASTM Committee F42 on AdditiveManufacturing Technologies and is the direct responsibility of SubcommitteeF42.05 on Materials and Processes.Current edition approved Sept. 1, 2016. Published November 2016. DOI:10.1520/F318716.2For referenced ASTM stand
13、ards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor,
14、 New York, NY 10036, http:/www.ansi.org.4Available from American Society for Quality, P.O. Box 3005, Milwaukee, WI53201-3005.5Available from American Welding Society (AWS), 8669 NW 36 St., #130,Miami, FL 33166-6672, http:/www.aws.org.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700,
15、West Conshohocken, PA 19428-2959. United States12.7 ISO Standards:6ISO 9001 Quality Management Systems: RequirementsISO 6983-2 Numerical control of machines Programformat and definition of address words Part 1: Dataformat for positioning, line motion and contouring controlsystemsISO 565:1990 Test si
16、eves Metal wire cloth, perforatedmetal plate and electroformed sheet - Nominal sizes ofopenings2.8 NFPA Standard:7NFPA 484 Standard for Combustible Metals2.9 OSHA Standards:8CFR Title 29, Chapter XVII, Part 1910 Occupational Safetyand Health StandardsOSHA Standards Checklist: Volume 15 Welding, Cutt
17、ingand Brazing3. Terminology3.1 DED Technology draws its terminology from severalsources, particularly from the 3D printing and welding indus-tries. Section 3.2 lists the terminology used in this guide, withmany definitions referring simply to other standards issued byASTM, ISO or AWS. Section 3.3 i
18、s then provided for thereaders convenience, re-listing some of the definitions mostimportant to an understanding of DED so the reader of thisguide does not have to cross-reference numerous other sourcesof information simply be able to read this guide. Please note,however, that the definitions given
19、in 3.3 are NOT keptup-to-date as the official definitions of these terms. The readerneeding the most up-to-date definition should reference theother sources listed.3.2 Definitions of Terms Specific to This Standard:3.2.1 active gases, ngases, including those containingcarbon dioxide, oxygen, hydroge
20、n and, in some cases, nitro-gen. Most of these gases, which in large quantities, woulddamage the deposit, when used in small, controlled quantities,can improve deposit characteristics.3.2.2 agglomerates, ncluster of primary particles heldtogether by weak physical interactions.3.2.3 alloy, nsee alloy
21、, AWS A3.0/A3.0M.3.2.4 arc plasma, nan ionized gas, used in all arc weldingprocess, through which an electric current flows.3.2.4.1 DiscussionArc processes suitable for DED arebased ostensibly on the gas shielded processes, namely GTA,PA, PTA, and GMA, and variants thereof.3.2.5 as built, adjsee as
22、built, ISO 52900, and 3.3.3.2.6 build platform, nsee build platform. ISO/ASTM529003.2.6.1 DiscussionIn ISO/ASTM 52900, the build plat-form of a machine is defined as the base which provides asurface upon which the building of the part/s is started andsupported throughout the build process. In DED, t
23、he buildplatform can also be a component that is to be repaired, andmay also be non-planar.3.2.7 capture effciency, nfraction of powder ejected fromthe deposition head that is incorporated into the built structure.Usually expressed in percent.3.2.8 carrier gas, ngas, typically inert, used to transpo
24、rtthe powder from the deposition head to the melt pool and alsoin some systems to assist the transport of powder from thestorage system to the deposition head.3.2.9 cast, nof a wire, diameter of the circle formed by alength of wire thrown loosely on the floor.3.2.10 cladding, nsee cladding, AWS A3.0
25、/A3.0M.3.2.11 cross stream, nflow, normally of inert gas, directedperpendicular to the optical axis of the lens being protected.3.2.12 cycle, nsingle cycle in which one or morecomponents, features or repairs are built up in layers in thebuild space of the machine. ISO/ASTM 529003.2.12.1 DiscussionDE
26、D is well suited to repair, featureaddition and remanufacturing applications. Throughout thisguide, the use of the terms “DED Build Cycle” and “DEDDeposition Cycle” are synonymous, irrespective of whether acomplete part is built, or a portion thereof, or a repair.3.2.13 defect, nsee defect, Terminol
27、ogy E1316.3.2.14 deposition head, nthe device that delivers theenergy and feedstock to the melt pool.3.2.15 deposition rate, nsee deposition rate, AWS A3.0/A3.0M.3.2.16 directed energy deposition (DED), nsee ISO/ASTM 52900 and 3.3.3.2.17 feed, na mechanism which delivers material, in theform of wire
28、 or powder, to the melt pool.3.2.18 filler metal, nsee filler metal, AWS A3.0/A3.0M.3.2.19 flaw, nsee flaw, Terminology E1316.3.2.20 focal spot, nsee focal spot, AWS A3.0/A3.0M.3.2.21 functionally graded material, ndepostied materialthat varies spatially in composition or structure, or both,resultin
29、g in corresponding changes in the properties of thematerial.3.2.22 gas metal arc (GMA), nsee gas metal arc welding(GMAW), AWS A3.0/A3.0M.3.2.22.1 DiscussionThe word “welding” in the AWS defi-nition conveys the joining of two or more pieces of material.As this is not the case for DED, the word “weldi
30、ng” is dropped.The remaining term characterizes the arc physics.3.2.23 gas porosity, nproperty, presence of small voids ina part making it less than fully dense.3.2.23.1 Discussiongas-filled flaws can form during theDED process or subsequent post-processing that remain in themetal after it has coole
31、d. This occurs because most liquidmaterials can hold a large amount of dissolved gas, but thesolid form of the same material cannot, so the gas forms flaws6Available from International Organization for Standardization (ISO), ISOCentral Secretariat, BIBC II, Chemin de Blandonnet 8, CP 401, 1214 Verni
32、er,Geneva, Switzerland, http:/www.iso.org.7Available from National Fire Protection Association (NFPA), 1 BatterymarchPark, Quincy, MA 02169-7471, http:/www.nfpa.org.8Available from National Safety Council (NSC), 1121 Spring Lake Dr., Itasca,IL 60143-3201, http:/www.nsc.org.F3187 162within the materi
33、al as it cools. Gas porosity may present itselfon the surface of the DED deposit or the flaw may be trappedinside the metal, which reduces strength in that vicinity.3.2.24 gas tungsten arc (GTA), nsee gas tungsten arcwelding (GTAW), AWS A3.0/A3.0M.3.2.24.1 DiscussionSee Discussion in 3.2.22.3.2.25 g
34、lovebox, ntypically a hermetically-sealed buildspace or chamber, normally filled with an inert gas, withinwhich material processing may occur. The chamber usuallyincludes gloves, through which an operator may reach tomanipulate components within the chamber without breakingthe seal, hence the name.3
35、.2.26 hatch spacing, nthe lateral distance betweensubsequent, adjacent passes of the deposition head whilstdepositing a layer.3.2.27 heat, nsee definition for powder lot per ISO/ASTM52900.3.2.28 helix, nof a wire, the vertical distance between oneend of a wire and the other end formed by a length of
36、 spooledwire thrown loosely on the floor. Helix can also be referred toas “pitch”.3.2.29 hopper, nthe converging portion of a bin. D61283.2.30 inert gas, nsee inert gas AWS, A3.0/A3.0M.3.2.31 intermetallic phases, ncompounds, or intermediatesolid solutions, containing two or more elements, whichusua
37、lly have characteristic properties and crystal structuresdifferent from those of the pure metals or the terminal solidsolutions. E73.2.32 interpass temperature, nsee interpass temperature,AWS A3.0/A3.0M.3.2.33 interpass time, nthe length of time between endinga particular layer and starting the next
38、 layer, or the length oftime between individual beads.3.2.33.1 DiscussionFurther to the AWS definition, inDED a common practice is to deposit multiple adjacentdeposition beads in succession (as when following a hatchpattern on a layer), and then allow the entire layer to coolbefore commencing the ne
39、xt layer. When this term is used inDED, it should be specified whether it refers to a dwellbetween the deposition of individual beads or entire layers.3.2.34 lack of fusion, nflaws caused by incomplete fusionbetween the deposited metal and previously-deposited metal.3.2.35 layer thickness, nprogramm
40、ed distance betweenone layer of the deposited material and the subsequent layer.3.2.35.1 DiscussionThe programmed layer thickness maydiffer from the actual layer thickness obtained. The actual layerthickness is determined by factors such as the power, feedstockfeed rate and travel speed.3.2.36 manuf
41、acturing lot, nsee ISO/ASTM 52900.3.2.37 manufacturing plan, na document that the pur-chaser may require in order to control the quality and repeat-ability of a deposition.Aplan includes, but is not limited to theproduction sequence, machine parameters, manufacturing con-trol system used in the prod
42、uction run, and quality checks.3.2.37.1 DiscussionManufacturing plans are typically re-quired under a quality management system such as ISO-9001and ASQ C-1.3.2.38 melt pool, nthe region of material melted by theheat source.3.2.39 minimum explosible concentration (MEC), ntheminimum concentration of a
43、 combustible dust cloud that iscapable of propagating a deflagration through a well dispersedmixture of the dust and air under the specified conditions oftest. E15153.2.40 mixed powder, npowder composed of two or moreconstituent powders of different compositions.3.2.40.1 DiscussionThe DED process al
44、lows both the useof powders mixed prior to the start of the deposition and alsomixing of powders enroute to the deposition head during thedeposition.3.2.41 near net shape, ncondition where the componentsrequire little post processing to meet dimensional tolerance.3.2.42 plasma arc (PA), nsee plasma
45、arc welding (PAW),AWS A3.0/A3.0M.3.2.42.1 DiscussionSee Discussion in 3.2.22.3.2.43 plasma transferred arc (PTA), nPlasma Trans-ferred Arc (PTA) is a constricted arc process similar to PlasmaArc Welding (PAW) in most respects. The arc is constrictedusing a water-cooled small diameter nozzle which re
46、duces thearc diameter and increases its power density. PTA differs fromPAW inasmuch as it is used predominantly as a surfacingprocess rather than a joining process. PTA also usually usespowder feed delivery (through powder ports in the nozzle or anannular feed around the nozzle) so is more flexible
47、in terms ofthe alloys that can be deposited, since more alloys tend to becommercially available in powder form than in wire form.3.2.44 powder blend, nquantity of powder made by thor-oughly intermingling powders originating from one or severalpowder lots of the same nominal composition.3.2.44.1 Disc
48、ussionA common type of powder blendconsists of a combination of virgin and used powder. Thespecific requirements for a powder blend are typically deter-mined by the application, or by agreement between the supplierand end-user.3.2.44.2 DiscussionIn traditional powder metallurgy, adistinction is made
49、 between blended powders and mixedpowders, in which case blended powders start with nominallyidentical composition and particle morphology, whereas mixedpowders are composed of powders of different compositions.See definition for mixed powder.3.2.44.3 DiscussionIf combined during the depositionprocess, for example by loading different powders into differ-ent feeders and combining at the point of deposition, thecorrect term is “mix”.3.2.45 powder feeder, nsee powder feeder, AWS A3.0/A3.0M.3.2.46 powder lot,
