Publications

Apr, 2026

Journal

Tailoring Thermal and Mechanical Performance Through Multimaterial Laser Powder Directed Energy Deposition of Copper and 17-4PH Stainless Steel

This study investigates the additive manufacturing (AM) processing, microstructural evolution, and resulting mechanical and thermal properties of multi-material components combining 17-4PH stainless steel and pure copper (Cu) fabricated via laser powder directed energy deposition (LP-DED). Conventional tooling steels exhibit limited thermal conductivity, significantly con…

Mar, 2026

Conference Paper

Integrating Computer-Aided Manufacturing Users with Directed Energy Deposition Guidelines

Mar, 2026

Conference Paper

Designing Remote Monitoring for Smart Manufacturing Facilities: Hazard Identification and Classification

This study investigates the process of hazard identification in complex manufacturing environments during the design phase, emphasizing the significance of the design process in developing designs that effectively mitigate hazards in contexts with numerous variables, such as a variety of machines, sensors, actuators, and agents. Through a mixed-methods approach, the object…

Mar, 2026

Conference Paper

Effect of Blown Powder Directed Energy Deposition Angle On Overspray Contamination

Blown powder directed energy deposition (DED) hybrid machine tools are particularly beneficial when the net shape of a component is to be manufactured in an additive and machined interleaved fashion. This investigation seeks to analyze the effect of the additive head lean angle relative to the part on blown powder DED surface contamination due to overspray. These hybrid DE…

Mar, 2026

Conference Paper

Hybrid Directed Energy Deposition of Geometrically-Complex Pressure Vessels for Advanced HIP Canning and Digitally-Driven Powder Metallurgy

Feb, 2026

Journal

Future Foundries: A Convergent Manufacturing Platform

This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking tra…

Aug, 2025

Journal

Detection of Part Porosity in Additive Manufacturing Using Machining

Monitoring of part porosity in additive manufacturing is critical for part qualification and process parameter development. This article describes the monitoring of porosity in additive manufacturing using machining. Grade 91 steel samples with different levels of porosity were additively manufactured using a laser blown-powder process. The samples were machined, and the t…

Jun, 2025

Journal

Impact of lead on an axisymmetric, single bead blown powder DED overhung geometry

Metal additive manufacturing can be utilized for the near net-shape manufacture of components in a layer wise technique. Traditionally, the buildup process is conducted in the direction of gravity or bottom to top in the vertical orientation; however, with the availability of commercial systems with additive heads or fixturing that can index from vertical, and the need to…

Sep, 2024

Journal

Process parameter translation strategies for variable directed energy deposition spot size using 316L, copper, and Inconel 625

Directed energy deposition (DED) is a form of additive manufacturing available across a variety of laser spot diameter values, often referred to as spot sizes. However, there is no method to easily transfer process parameters across discrete spot sizes, leading to DED process parameters that are equipment specific and not widely applicable. In this study, a strategy is pro…

Sep, 2024

Journal

Coaxial Color Channel Focus Evaluation to Estimate Standoff Height in Directed Energy Deposition Additive Manufacturing

Directed energy deposition (DED) is an additive manufacturing process that is being rapidly adopted by industry and is well suited for the fabrication of complex components in a variety of metal alloys. In laser cladding systems such as DED, powder is blown in a stream to a metal substrate coincident with a laser necessary to deposit molten metal with 3D spatial control. T…

Aug, 2024

Journal

Multiscale characterization of an additively manufactured property graded Ni-base alloy for molten-saltssupercritical-CO2 heat exchangers

The sequential optimization of strength and corrosion resistance in conventional alloy design procedures often results in a tradeoff between environmental degradation and optimal mechanical properties. A concurrent optimization of these two material properties is essential to efficiently develop high temperature alloys that can withstand harsh environments increasingly req…

Aug, 2024

Journal

Hybrid additive manufacturing of AISI 316L via asynchronous powder and hot-wire laser directed energy deposition