Proceedings of the Canadian Society for Mechanical Engineering International Congress

31st Annual Conference of the Computational Fluid Dynamics Society of Canada

CSME/CFD2024
May 26–29, 2024, Toronto, Ontario, Canada

Exploiting a Multi-Axis Hybrid Directed Energy Deposition Process to Develop

a Collision and Support Free Build Solution for a Closed Impeller

Marzia Saghafi1*, Ruth Jill Urbanic1, Bob Hedrick2, Hamoon Ramezani2

1
Mechanical, Automotive, & Materials Engineering Department, University of Windsor, Windsor, Ontario, Canada
2
CAMufacturing Solutions Inc, Windsor, Ontario, Canada

*Saghafi@uwindsor.ca

Abstract— In today's economy, ensuring continuous these challenges [2-4]. AM is emerging as a solution, offering
production system operation while minimizing downtime is agile manufacturing processes that eliminate tooling
paramount. However, traditional manufacturing methods requirements [5]. While AM shows promise, concerns about
encounter difficulties in replacing outdated equipment and cost, reliability, and technology readiness persist. Studies have
managing spare parts inventory. Additive Manufacturing examined AM's effectiveness for supplying spare parts,
(AM), especially Directed Energy Deposition (DED), presents highlighting its benefits for smaller components but limited
flexible solutions, albeit with concerns regarding cost and cost competitiveness for larger ones [6,7]. Optimization models
reliability. Researchers are investigating DED AM's efficacy demonstrate AM's potential to improve supply chain resilience
and profitability, particularly in e-commerce and aviation [8,9].
in spare parts supply and its potential to enhance supply chain
Despite AM's advantages, its viability depends on factors such
resilience and profitability. Recent studies have delved into
as stocking costs, failure rates, and post-processing operations
DED AM for both manufacturing and repairing high-wear to enhance part reliability [10,11]. Research continues to
industrial components like turbine blades and impellers, explore AM's role in spare parts supply chains and its impact
showcasing its viability and cost-effectiveness. This study on overall supply chain performance and profitability [12].
focuses on devising a tailored manufacturing process plan for Additionally, Ulutan et al. [13] have shown that post-
a closed impeller, emphasizing DED AM and hybrid processing operations to increase part reliability can lead to
manufacturing (HM) capabilities in overcoming challenges AM becoming the main source for parts, even if their reliability
such as overhang geometries, achieving desired surface finish, is lower than traditionally manufactured parts.
and meeting tight tolerance requirements. Strategies for In addition to spare parts manufacturing, recent studies
collision avoidance specific to this geometry are also explored have explored integrating AM into existing traditional
to maximize HM potential. Ongoing research seeks to further manufacturing networks. Ahmed et al. [14] demonstrated AM's
optimize DED AM and HM processes, promising increased utility for supplementing part shortages and serving as the
production flexibility and supply chain resilience. This primary supply source for specific demand points. Nyamekye
research represents a significant advancement in et al. [15] found that DED and other AM technologies can
comprehending and leveraging the potential of DED AM reduce energy and material usage in titanium parts.
within industrial contexts. Recent studies have delved into the utilization of AM for
both manufacturing and repairing high-wear industrial parts
Keywords-Additive Manufacturing (AM); Directed Energy such as turbine blades, propellers, and impellers. Investigations
Deposition (DED); Hybrid Manufacturing (HM); Process into Powder Bed Fusion (PBF) and material extrusion
planning; Intricate geometry; Closed impeller techniques, alongside DED processes, have exhibited potential
for both repair and manufacturing purposes. Notably, Sikan et
I. INTRODUCTION al. [16] demonstrated the successful repair of titanium blades
using DED, while Dugar et al. [17] highlighted the cost-
In today's economy, maximizing production system effectiveness of DED in manufacturing hollow blades
availability while minimizing downtime is crucial. compared to alternative methods.
Maintenance plans and inventory management are vital for Despite the acknowledged potential of DED and HM
achieving these goals, with an increasing focus on high- processes for handling intricate geometries, there exists a
reliability preventive maintenance policies [1]. However, notable gap in the literature concerning these specific part
replacing long-standing equipment poses challenges when types. This research aims to address this gap by presenting a
manufacturing systems become obsolete. Spare parts manufacturing process plan tailored for a closed impeller. The
management is essential but can lead to increased inventory study will focus on proposing solutions for challenges related
costs. Researchers are exploring various strategies, including to overhang geometries, collision avoidance, and achieving
remanufacturing and spare part inventory control, to address
desired surface finishes. This endeavor will serve as a valuable innovative building strategies. A similar approach was
case study for geometries with similar specifications. employed in the fabrication of a closed impeller.
Moreover, research has indicated the potential for
integrating AM into spare part management and the upgrading
of manufacturing facilities. While Powder Bed Fusion (PBF),
Stereolithography (SLA), and Fused Filament Fabrication
(FFF) AM processes have been extensively studied in the
context of spare parts literature, research on DED and HM
remains limited. However, DED AM process planning exhibits
promising capabilities for automating processes and
manufacturing complex geometries with multi-axis
capabilities. An overview of the DED process family and HM
will be provided in subsequent sections.

A. About DED and HM

Figure 1. Multi-axis approach
DED, one of ASTM's defined categories, involves bead-
based deposition capable of creating or repairing parts using
various materials, including multiple materials per layer. Four
DED subcategories are distinguished by their energy source:
laser beam, electron beam, wire arc, and plasma arc [18]. Laser
beams directly melt feedstock, offering high build rates, while
electron beams, working in a vacuum, produce fine surface
finishes, suitable for aerospace industries. Wire arc AM, or
WAAM, melts wire feedstock with an electric arc,
advantageous for larger parts and diverse materials. Plasma arc
AM combines plasma transferred arc welding with AM,
suitable for printing larger parts without fine surface finishes,
like those in oil, sands and mining industries. HM integrates a) Multi-axis partitioning strategy b) Final part
Figure 2. Multi-axis partitioning approach for building a dome (adapted from
machining with AM, enhancing geometric design freedom [20])
while addressing surface finish and feature tolerance issues
[19]. Laser-based and WAAM systems are prominent in HM
research, with transferrable AM build solutions applicable to
multi-axis DED systems.

B. Multi-Axis Machine Concept

In Figure 1, a typical structure of a DED AM/HM machine
is illustrated. It comprises rotary axes arranged in a table-table
stack configuration, although alternative setups are feasible.
Utilizing multi-axis tool paths enables the fabrication of
components with overhanging geometries without necessitating
support structures; however, careful consideration of collision Figure 3. Variable layer height and overhang geometry (Courtesy of Phillips
avoidance is essential. This can be achieved by integrating Additive)
lead/lag angles (aligned with the direction of toolhead Additionally, in another instance, a curved pipe was
movement) and tilt angles (perpendicular to the direction of successfully manufactured utilizing the DED laser powder
toolhead movement). Several DED AM toolpaths and build process. The outcomes of this endeavor have been delineated in
strategies (developed by the authors) have been employed by Figure 3, with the strategy of variable layer height and
researchers and industrial partners (Figures 2-4) and are adjustment of the tool head angle employed in creating the
leveraged for this research. toolpath. Notably, the fabrication of this component was
Introducing motion adjustments to reorient the component executed using a Haas UMC-750 machine.
during the deposition process ensure that the previously When combined with machining, this approach enables
deposited layers of the part provide support for the newly new design and manufacturing possibilities. This concept is
added layer. In a 5-axis system, when the tilt angle increases to used to plan the manufacturing process for a customized
match the overhang angle, prevent the deposited material from component, where a completely machined internal surface was
collapsing [20]. achieved using HM (Figure 4). The manufacturing of this
This building strategy has been effectively implemented in custom part has employed simultaneous deposition to avoid
building solutions for a thin-wall hemisphere dome (Figure 2). collisions. An identical approach will be used for the closed
Notably, this design exhibits continuously variable overhang impeller case study. This component was fabricated using a
angles in two directions [20]. This exemplary case underscores Mazak VC-500A/5X AM HWD machine.
the efficacy of partitioning a component in paving the way for
 requirements. HM processes address these challenges by
combining material addition and internal surface machining
simultaneously.
Due to the impellers' complex geometry, challenges arise in
AM planning, including thin walls, overhanging geometry
without support material, and minimizing collisions during
multi-axis builds. To overcome these, we use commercial AM
planning software (APlus) and Mastercam computer-aided
manufacturing (CAM) to generate AM and machining
toolpaths. Our solutions involve adjusting build planes, tool
tilts, slicing methods, and design modifications applicable to
a) Final part built by hybrid manufacturing with completely machined internal similar geometries.
surfaces We utilize software tools like backplot and machine
simulation to identify collision zones and re-program
accordingly. Some features require support structures,
prompting design changes for a DED AM solution.
Decomposition, redesign, and collision avoidance rules are
introduced. The research assumes 5-axis hybrid machine tools
and uses 316L stainless steel as the build material. Future work
includes analyzing heat cycling and evaluating resulting
mechanical and physical properties.

b) Deposition simulation using APlus c) Deposition process

software

Figure 5. Isometric view of closed impeller

III. RESULTS

A. Design for Manufacturing

Two general slicing concepts are available for this
d) Machining simulation using e) Machining process geometry: planar and radial. Examining the geometry depicted
MasterCAM in Figure 6 (a) the area between two back-to-back blades
Figure 4. Multi-axis approach for fabricating three flanges part using hybrid resembles a hollow box without a cap, with overhang angles
manufacturing (Courtesy of Mazak Corporation)
present in the bottom and top cap if a planar slicing approach is
The primary objective of this study is to devise process chosen. Conversely, employing a radial slicing solution (slicing
planning strategies tailored to DED and HM, with a specific the geometry using concentric circles) reveals no support
focus on intricate geometries. In light of its complex geometric geometry at the center for blades and the top cap.
features and the presence of overhanging sections, a closed It appears that some alterations to the CAD model are
impeller was chosen as the subject of investigation. The goal of necessary to enable the part to be sliced effectively. Given the
this paper is to achieve fully machined surfaces across the more suitable nature of radial slicing for this rotary-shaped
entirety of the final component. Throughout this study, we have component, design-for-manufacturing adjustments have been
simulated the devised manufacturing process plan based on made to facilitate printing the part on a cylindrical substrate.
various strategies previously tested in our research endeavors The initial step involves designing a conical central core for the
[21,22] (Figure 2 and 4). impeller, providing adequate support to build the blades,
bottom, and top sections by utilizing radial slicing operations.
II. MATERIAL AND METHODS These added sections will be removed subsequently. A
The study focuses on creating a manufacturing strategy for cylindrical bar has been selected as the substrate (see Figure 6
an industrial-grade closed impeller. Traditionally, these (b)), and thus, a cylindrical tail has been appended to the
impellers are made through casting, with occasional machining. central core. All these supplementary sections will undergo
However, for the specific impeller shown in Figure 5, relying machining at the final stage. Figure 6 (a) depicts this
solely on machining is not feasible. Casting often leads to modification in the CAD model.
challenges like surface finish issues and strict dimensional
 threshold angle is dictated by the capabilities of the machine
and material, representing the maximum overhang angle that
can be deposited on the underlying layer.

a) Change in CAD model to add central core and b) Substrate

cylindrical tail
Figure 6. Design for manufacturing concept

B. Decomposition Rules and Slicing Method

The decomposition strategy holds significant importance in
the AM process planning, typically contingent upon the
geometry and the slicing methodologies at hand. In the context
of this case study, the revised CAD model comprises two
rotationally symmetric sections, namely the bottom and top a) Helical slicing (top and side view) b) Top and bottom sections toolpaths
cap, along with the blades, which can be radially deposited on Figure 8. Top and bottom sections deposition
the central core. Consequently, the geometry has been
decomposed into three distinct parts: the bottom section
(depicted in yellow in Figure 7), the top cap (illustrated in
green), and the blades (highlighted in purple).
Given that both the top and bottom sections exhibit
rotational symmetry, the related geometry is sliced into
concentric helices around the substrate axis for deposition. a) Blades deposition result
Figure 8 illustrates the deposition process for these rotary
sections. For illustrative purposes, the additive process employs
a 1 mm bead with a height of 1 mm. Additional stock of 2 mm
is provided on the inner and outer surfaces, along with an extra
layer at the outer diameter to ensure material for final
machining. The blades are sliced separately using radial
toolpaths, with each toolpath being concentric with the
substrate cylinder (refer to Figure 9). Again, 2 mm extra stock
is used for final machining purposes. Incorporating radial and
b) Radial slicing for blades and considered c) Maximum applicable tool
helical toolpaths with careful consideration of the appropriate lead angle head angle without collision
overlap and bead offset strategies has been demonstrated to Figure 9. Blades deposition
produce void-free results [22]. Therefore, employing these Concerns arise regarding potential collisions between the
toolpaths mitigates concerns regarding void formation within tool head and deposited sections due to the tool head's
the printed part. geometry. However, no such issues were encountered in the
closed impeller examined in this study. In the event of a greater
overhang angle in the blades leading to potential collisions, the
implementation of support structures would become necessary.
Figure 10 illustrates these support structures laid on the central
core or the next blade. Should support structures be required,
machining would be necessary to remove them from the core
and base blade after several layers of deposition.

Figure 7. Decomposition strategy for changed model

D. Strategies for Collision Avoidance
In multi-axis machines, collision avoidance is a crucial
C. Strategies for Overhang Geometries consideration for machining operations. This concern becomes
The decomposition strategy effectively mitigates overhang particularly significant when dealing with the intricate
concerns in rotationally symmetric sections, but introduces a geometry of AM DED tool heads, especially when
radial overhang angle in the blades. To address this challenge, a incorporating angles such as lead, lag, or tilt angles.
lead angle is required to ensure that during deposition, the The determination of the maximum allowable angle in the
angle between the tool vector and the tangent line to the tool head perpendicular to the deposited layer is imperative.
overhang surface remains below the acceptable threshold of Illustrated in Figure 9 (c) which is a schematic representation
10°, as determined for this case study (see Figure 9 (b)). This of a DED tool head, showcasing its geometry, which is utilized
to ascertain the maximum allowable angle without risking E. Machining
collisions with underlying layers. In the case study involving The primary objective of this process planning initiative
the closed impeller, it was noted that the radial overhang angle was to ensure the attainment of machined surfaces across all
within the blades is below 34 degrees. Given a predetermined facets of the part, encompassing both internal and external
threshold of 10 degrees for the overhang angle, taking into surfaces, while maintaining stringent dimensional tolerances.
account the properties of the chosen material and machinery, a In order to achieve a superior surface finish, particularly
build strategy was formulated. This strategy incorporates a lead given the presence of overhang geometries within the part, it
angle of 24 degrees to adeptly manage the overhang geometry, was imperative to sequence the machining of internal surfaces
thereby mitigating the risk of collisions during the following each additive cycle. The geometry was strategically
manufacturing process. segmented into radial sections. Following the deposition of a
predetermined number of layers, aligned with the machining
capabilities, a precision machining operation was conducted to
refine the internal cavities. Subsequently, upon the completion
of all deposition phases, attention was directed towards
finishing the outer surface. Subsequent to this, the central core
was extracted via a milling process, thereby reinstating the part
to its original design specifications. Remarkably, all
manufacturing processes for this part could be seamlessly
executed within a singular machine setup.
Figure 10. Required support structure Figure 11. Helical re-tract motion
for dealing with high overhang angle IV. DISCUSSION
in blades
Due to the selected decomposition rule, which involves two Efficiently producing small quantities of service parts often
rotary symmetric sections and blades sliced separately, there proves challenging with traditional manufacturing methods like
arises a potential collision issue if these three sections were to machining, forging, and casting, especially due to their reliance
be deposited independently. To address this challenge, the on expensive tools. AM technologies offer innovative solutions
following algorithm has been devised: with enhanced design flexibility. However, existing research
- Deposit one layer of the top section. tends to overlook factors such as size constraints, production
- Deposit one layer of the bottom section. times, post-processing requirements, and challenges related to
- Deposit one layer of the blades. varying mechanical properties and surface roughness [19].
- Proceed to the next layer. HM combines additive and subtractive manufacturing
Figure 12 visually depicts the sequential deposition of these strengths, particularly beneficial for low-volume production
three components, ensuring collision avoidance between the [23]. HM enhances part design feasibility and facilitates the
tool head and the deposited sections. fabrication of complex geometries previously unattainable. It is
In the pursuit of further mitigating collision risks between also utilized for repairing service parts [24]. Future research
the tool head and deposited sections, a helical re-tract motion aims to extend considerations to repair processes. General
strategy has been adopted. During the re-tract motion phase process planning strategies are continually evolving in
(devoid of deposition motions of the tool head), the tool head generative machining, necessitating similar advancements in
emerges perpendicular to the deposited sections and DED AM processes [25]. A geometry classification code has
subsequently navigates in a circular arc to transition to the next been developed to facilitate a generative additive approach
point. Such orchestrated movements significantly reduce the [22].
likelihood of collisions with the underlying layers. (Figure 11) This study is centered on a closed impeller and the
While these measures notably diminish the probability of application of HM. It aims to develop comprehensive Design
collision between the tool head and deposited sections, it's for Additive Manufacturing (DfAM) principles and build
essential to underscore the pivotal role of possessing a precise strategies to realize the fabrication of this part in low volumes
machine model and a comprehensive setup for simulation. with high surface finish quality, a capability unattainable
Refer to Figure 12 (b) for a visualization of this concept. through conventional manufacturing methods. In HM process
planning, decomposition and slicing methods and component
redesign are crucial for enhancing geometric quality, reducing
residual stress [26], and minimizing support materials. A
comprehensive process planning solution should integrate
additive and machining operations, along with final part’s
functionality. In ongoing research, we are developing a new
heat dynamics model, which promises to predict heat dynamics
for complex geometries and DED toolpaths. This model will
enable us to assess various build strategies in terms of residual
a) slicing top, bottom, and blades b) Machine set up simulation for stresses, distortion, and other mechanical properties, aiming to
sections simultaneously additive process
Figure 12. Simultaneous deposition
find the optimal solution. Collision avoidance, significantly
influenced by tool head geometry and machine design, remains
critical. Various strategies explored in this study enhance DED
and HM process functionality [27,28].
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