A comprehensive review of twin-wire direct energy deposition for functionally graded materials: Microstructures, properties and defects
Arun Murugan, Venkatesh Chenrayan, A. Saravanakumar, Kiran Shahapurkar, Jana Petrů, Muhammad Nasir Bashir, Manzoore Elahi M. Soudagar
Abstract
Modern industrial manufacturing sectors are experiencing a great challenge in consistent product development, which requires high-performance material manufacturing with minimal lead time. The conventional monolithic materials are slowly becoming obsolete since the performance of the in-situ alloy, composite, and high-entropy alloys is phenomenal. Besides, the metal additive manufacturing (AM) is a versatile one, which minimises the lead time with near-net-shape manufacturing. However, the absence of material flexibility restricts this technique to limited applications. The advancement in Wire Direct Energy Deposition (WDED) by melting and depositing the two wires simultaneously, called Twin-Wire Direct Energy Deposition (T-WDED), upholds the higher deposition rate and in-situ alloying to tailor the component. This study overviews the novel implementation of T-WDED in the development of various in-situ alloys, their microstructure induced, properties enhanced, and the probable defects encountered. Apart from this, the study overviews the evolution of functionally graded materials (FGM) and tailor-made components by mitigating the wire feed rate. Further exploration and scientific discussion on the performance enhancement of the T-WDED materials in connection with the microstructure and defects are of prominent interest to the product development industries and researchers. Hence, the study proves its significance in rapid manufacturing with customised materials.