Design and Commissioning of a Hybrid Additive Manufacturing System Combining Inkjet Deposition and Laser Powder Bed Fusion

Abstract

Capabilities to combine multiple metal and/or ceramic materials in single components, and/or to achieve desired gradients in composition, will advance the performance of future propulsion and energy conversion systems. Multi-material and gradient capabilities have been demonstrated for metals in both powder bed and directed deposition additive manufacturing (AM) techniques; however, the dimensional fidelity and spatial precision of composition control is limited for several reasons. Here the design, fabrication, and preliminary validation of a new hybrid AM system combining inkjet printing with laser powder bed fusion (LPBF) for manufacturing compositionally graded components is presented. In the hybrid inkjet-LPBF process, a pattern of ink is deposited in a two-dimensional pattern to dictate compositionally modified regions prior to, or following, the spreading of each powder layer. Solids (e.g., nanoparticles) in the ink combine with the base powder to achieve locally controlled in situ alloying within the AM process. Key design considerations for the system including thermal isolation of the inkjet system, temperature control of the build volume (up to 500C), and atmosphere control are discussed.