Process analysis of direct laser melting to fabricate layered hybrid beads

The successful fabrication of layered hybrid beads by DLM process is limited by dissimilar melting ranges of different powders. For the application of DLM process into manufacturing industries, target mechanical properties of final product must be achieved. Process analysis was performed for the DLM fabrication of layered hybrid beads by using stainless steel (SS 316L) and titanium powders. For the analysis of fabrication characteristics, single hybrid bead was formed using SS316L powder onto the base plate and then Ti powder was melted onto the previous melted layer. In addition, multi-layer hybrid beads were fabricated for the analysis of the layering effects between them. From these studies, the effects of the processing parameters, such as laser power, scan rate and scan line spacing on surface morphology were characterized and optimum processing conditions for the DLM fabrication of layered hybrid beads were developed.