Directed Energy Deposition
Directed Energy Deposition (DED) describes processes where focused energy sources (laser, electron beam, plasma arc) melt wire or powder feedstock and deposit material along programmed toolpaths. DED is valued for repair, feature addition, and large-scale builds.
Additive Friction Stir Deposition (AFSD) is a solid-state process: a rotating consumable rod or plate of feedstock is softened by frictional heat and plastically deformed onto a substrate, enabling near-net-shape builds without melting. AFSD avoids defects such as porosity and solidification cracking that can occur in melt-based DED.
DREAMS Lab Research
Our research explores multi-scale modeling and experimental evaluation of microstructure in DED. We focus on optimizing deposition parameters to minimize residual stresses and distortion, developing new toolpathing strategies and incorporating scanning for error detection and resolvement. In addition, the lab engages in WAAM adaptation of robotic systems for large-scale Multi-axis builds.