Maintenance for Directed Energy Deposition 345

Access levels

The permissions or restrictions that a user has within a machine or software system. Access levels allow different personnel to use different software functions based on their job role or training.

Additive manufacturing

AM. The process of joining or solidifying materials to make an object from a three-dimensional computer model. Additive manufacturing methods typically build up layers of material to create an object.

Build chamber

The area contained within an additive manufacturing (AM) machine where the part is actually built. Many build chambers are enclosed to improve the safety of the manufacturing operation.

Build plate

A removable flat surface on which an additively manufactured part is constructed. Build plates are removable build platforms and must be carefully centered and leveled to ensure a successful build.

Carrier gas

An inert gas used to deliver powdered material to the melt pool in a DED system. Carrier gas flow is related to the deposition rate.

Ceramic

A hard, brittle material that can withstand high temperatures and resist corrosion. Ceramics, which include metal oxides, nitrides, and glasses, are sometimes used as build material in additive manufacturing.

Chips

A small piece of material that is removed from a workpiece. Chips can get caught between fixture components and the workpiece, reducing finished part accuracy.

Composites

A group of materials that are made by combining two or more of the following groups: metals, plastics, and ceramics. Composites are sometimes used as build material in some additive manufacturing methods, such as material extrusion and directed energy deposition.

Compressed air

Air that has been forced into a small space at high pressure. Compressed air is often used to clean electronics.

Connectivity

The capability of computer systems and devices to share information across networks. Connectivity helps advance industry but also poses cybersecurity risks.

Cyber attacks

An effort to disrupt, disable, or gain illegal access to a digital device or network. Cyber attacks include hacking, phishing, and installing malware.

Cybersecurity

Protection against criminal or unauthorized access to computer networks, programs, and data. Cybersecurity has become a major industrial concern as networking and connectivity have increased.

Data analysis

The process of performing various calculations on organized data sets to gain new information from the data. Data analysis is required for predictive maintenance.

Data capture

The process of collecting or reading encoded data and converting it to an electrical signal. Data capture for DED machines is accomplished using sensors.

Data integrity

The degree of accuracy and usability of stored data. Data integrity is necessary to produce accurate and usable data insights.

DED

Directed energy deposition. An additive manufacturing process in which focused thermal energy is used to melt materials as they are deposited. DED is often used with powdered or wire metal feedstock.

Default settings

Pre-configured features, options, or functions that an equipment manufacturer sets up prior to a customer receiving the equipment. Default settings on DED machines should only be accessible to trained technicians.

Deposition head

A DED machine component that includes the energy source and dispensing nozzle. Deposition heads are used in laser metal deposition (LMD) processes.

Directed energy deposition

DED. An additive manufacturing process that uses focused thermal energy to melt materials as they are deposited. Directed energy deposition is often used with powdered or wire feedstock.

Dust mask

A protective nose and mouth cover that filters out some airborne particles. Dust masks are effective at filtering out large particles, such as sand used in binder jetting, but cannot filter out smaller particles, such as nanoscale metal and plastic particles.

Electron beam

A narrow stream of electrons that create focused thermal energy. Electron beams are used in some additive manufacturing processes to fuse materials.

Electron beam freeform fabrication

EBFF. An additive manufacturing technology developed by NASA that uses an electron beam and metal wire feedstock to build and repair parts. EBFF, sometimes referred to as EBF3, uses an electron beam and metal wire feedstock .

Energy source

The component on a DED machine that melts the material to form the part. DED energy sources include lasers, wire arcs, and electron beams.

Environmental controls

Equipment designed to clean or control the environment. Environmental controls can include filtration systems, ventilation systems, or other cleaning devices.

Error codes

An alphanumeric message that references a specific cause of malfunction. Error codes appear on the DED machine interface and can be cross-referenced in the manual.

Feed lines

Flexible tubes or pipes that deliver feedstock from the feeder to the melt pool in DED systems. Feed lines for DED machines may deliver wire or powder feedstock, depending on the machine type.

Feed system

The method or mechanism that delivers material to the part build. DED machine feed systems include powder feed and wire feed systems.

Five-axis

Machine control that can execute movement along three linear axes and two rotational axes. Five-axis machining capabilities can allow hybrid DED deposition heads to access areas of a part that are difficult to reach otherwise.

four-axis

Machine control that can execute movement along three linear axes and one rotational axis. Four-axis DED machines rotate the workpiece in a fourth axis.

Gantry

The mechanized bridge on some DED machines that moves the tool in three linear axes. A gantry's movement is controlled by the G code program run by the machine's software.

human-machine interface

HMI. A device connected to a machine that allows operators to monitor and control a machine or process. A human-machine interface may have a touch screen or control pad.

Hybrid manufacturing

A manufacturing approach that produces parts by combining multiple manufacturing processes in a single digital workflow or on a single machine. Hybrid manufacturing may describe a variety of manufacturing process combinations but is most often associated with combining additive and subtractive processes.

Image sensors

A device that detects and conveys information used to make an image. Image sensors capture surface data when 3D scanning a part.

Inert

A gas or other substance that does not chemically react with the substance it contacts. Inert gases include nitrogen, helium, and argon.

Inspection

Examination of a component or system to ensure that it is operating correctly. Inspection for proactive maintenance involves measuring and comparing various parameters.

Laser beam

An intense beam of light that can be precisely aimed and controlled. Lasers are sometimes used to selectively solidify or fuse materials in additive manufacturing methods, including directed energy deposition, powder bed fusion, and vat photopolymerization.

Laser cleaning

The use of machines that use laser beams to loosen debris or contaminants on a surface. Laser cleaning is a safer cleaning method than compressed air.

linear axes

An imaginary straight line that describes side-to-side, front-to-back, or up-and-down machine movements. Linear axes typically include the X axis, Y axis, and Z axis.

local area networks

LANs. A type of wired network that enables communication between a group of computing devices in a specific geographic location. Local area networks are commonly used by manufacturers and other organizations to limit the exchange of digital information to onsite devices and prevent outside access.

Lubricant

A substance such as oil or grease that is used to prevent friction between two surfaces in relative motion. Lubricant is sometimes used for wire feed systems to reduce friction between the electrode and the feedline.

Machine failure

The complete loss of performance in a component or a system. Machine failure can result from electrical and mechanical faults within a system.

Machining

A manufacturing process that involves removing material to form an object. Machining can occur using traditional methods, like turning, drilling, milling, and grinding, or with less traditional methods that use electricity, heat, or chemical reaction.

Material hoppers

A container used to hold raw materials for use in an industrial process. Material hoppers used in metal AM processes hold powdered metal.

Melt pool

An area of liquefied material, usually metal. Melt pools are created in directed energy deposition (DED) to fuse powdered metal or metal wire in layers to form a solid part.

Metal

A naturally occurring material with high strength, hardness, and electrical and thermal conductivity. Metals are categorized as either ferrous or nonferrous.

Microfiber

A synthetic fiber finer than one denier, commonly used for lint-free cleaning. Microfiber cloths are preferred for wiping down components inside a DED machine build chamber.

Near-net shape

A part with dimensions that are close to its final specified form after initial manufacturing steps. Near-net shape parts require little subsequent machining.

Nitrile

A low-cost copolymer that protects against various chemicals. Nitrile is highly puncture resistant compared to latex.

Nozzle

The component on a DED machine that dispenses the material. DED nozzles dispense either powder or wire feedstock.

Occupational safety and health administration

OSHA. A federal agency under the U.S. Department of Labor that ensures safe working conditions and helps to reduce workplace injuries, illnesses, and deaths. The Occupational Safety and Health Administration creates regulations that ensure employees work in a safe and healthy environment.

Pascals

Pa. A unit of pressure that measures the number of newtons per square meter. A pascal unit is also known as a newton per square meter, which is derived from the International System of Units (SI).

Passwords

A series of characters, known only by authorized users, that allow the users to access an otherwise locked digital system. Passwords effectively prevent unauthorized access as long as they are not shared or discovered by unauthorized users.

Personal protective equipment

PPE. An article of clothing or a device worn to minimize exposure to hazards and prevent injury. Personal protective equipment may include safety glasses, safety gloves, ear plugs, respirators, or steel-toed boots.

Planned maintenance

Maintenance that is performed purposely and regularly in order to prevent machine deterioration or breakdown. Planned maintenance involves performing maintenance on a scheduled basis and helps prevent unscheduled downtime .

Planned maintenance optimization

PMO. A manufacturing improvement method that increases production and reduces waste through continuous attention to the condition of machines and processes. The main goal of planned maintenance optimization is to maximize equipment usefulness across its lifespan.

PM

Preventative maintenance. Regularly scheduled maintenance tasks performed to prevent unexpected equipment failure. PM can be improved by using data for predictive maintenance.

PMO

Planned maintenance optimization. A manufacturing improvement method that increases production and reduces waste through continuous attention to the condition of machines and processes. The main goal of PMO is to maximize equipment usefulness across its lifespan.

Pounds per square inch

psi. A measurement of pressure used in the English system. Pounds per square inch is the pressure resulting from a force of one pound applied to an area of one square inch.

Powder feed systems

A machine or component that delivers powdered material feedstock. Powder feed systems may need to be vacuumed and wiped down during DED maintenance.

PPE

Personal protective equipment. An article of clothing or a device worn to minimize exposure to hazards and prevent injury. PPE may include safety glasses, safety gloves, ear plugs, respirators, or steel-toed boots.

Predictive maintenance

PdM. A maintenance approach that involves collecting and analyzing data in order to service a machine before maintenance issues arise. Predictive maintenance involves performing maintenance when conditions arise that have led to problems in the past, which helps prevent unscheduled downtime.

preventative maintenance

PM. Regularly scheduled maintenance tasks performed to prevent unexpected equipment failure. Preventative maintenance can be improved by using data for predictive maintenance.

Repeatability

The ability of a machine or process to continually deliver consistent and uniform results. Repeatability is crucial for efficiently producing parts that meet quality requirements.

Respirator

A breathing device worn to prevent inhalation of hazardous substances. Respirators may purify air or supply air to the wearer.

robotic arm

A programmable or remote-controlled device that simulates the movement of a human arm. Robotic arms are used in a variety of assembly and manufacturing applications, including DED.

rotational axis

An axis that describes turning or rotation around a linear axis. Rotational axes often include the A axis that rotates around the X axis, the B axis that rotates around the Y axis, and the C axis that rotates around the Z axis.

Seals

An intentional obstruction designed to keep materials, such as powder granules or fluids, inside a system. A seal prevents leakage and contamination.

Sensors

A device that detects a change in a physical condition and turns it into an electrical signal. Sensors are common analog input devices that respond to variable conditions, such as pressure, temperature, or flow.

Shielding gas

A gas that protects the melt pool and energy source from atmospheric contamination. Shielding gas is supplied by a cylinder and flows through welding torch or deposition head on a DED machine.

Spatter

Liquid metal droplets expelled during a welding or DED process. Spatter can leave undesirable dots of metal on a workpiece surface.

support structures

The substance used to create the support structures for an additively manufactured part. Support structure material is often slightly different from the build material so that it can be more easily removed once the part is finished.

three-axis

Machine control that can execute linear movements along two horizontal axes and one vertical axis. Three-axis DED machines can build or repair some basic parts efficiently but are less suitable for more complex parts.

Troubleshooting

A systematic approach to solving problems quickly and efficiently. Troubleshooting often involves a logical process of elimination to identify the source of a problem.

Ultrasonic cleaning

The use of machines that use ultrasonic sound waves to loosen debris or contaminants on a surface. Ultrasonic cleaning is a safer cleaning method than compressed air.

Vacuum-sealed chamber

A sealed enclosure from which air is removed by a vacuum pump. Vacuum-sealed chambers surround the entire build area in some DED systems.

Vibration sensors

A smart device that monitors machine component vibration levels. Vibration sensors can detect hazardous machine conditions.

Warranty

A guarantee provided by the manufacturer covering repair or replacement of defective machine components within a specified time.

welding torch

The instrument used to generate the arc or flame for welding. The welding torch may hold an electrode or release gases that produce a flame.

Wire arc

The area in which electricity jumps from an electrode to a conductor to produce extreme heat and light. Wire arcs are used in thermal welding and cutting applications, as well as in directed energy deposition.

Wire feed systems

A machine or component that delivers material feedstock in the form of a wire spool. Wire feed systems may need to be cleaned during DED maintenance.

Wire feeder

A device that delivers a wire electrode to the melt pool. The wire feeder may be built inside the power source or be an external device set beside it.

workpiece

A part that is in the process of being manufactured. A workpiece may be a complete product by itself or one component of a product consisting of many parts.

Worktable

The part of a DED machine that supports the workpiece. The worktable, or table, can move along a combination of linear and rotational axes, depending on the configuration of the machine.