ASTM F3187-16(2023)
(Guide)Standard Guide for Directed Energy Deposition of Metals
Standard Guide for Directed Energy Deposition of Metals
SIGNIFICANCE AND USE
5.1 This guide applies to directed energy deposition (DED) systems and processes, including electron beam, laser beam, and arc plasma based systems, as well as applicable material systems.
5.2 Directed energy deposition (DED) systems have the following general collection of characteristics: ability to process large build volumes (>1000 mm3), ability to process at relatively high deposition rates, use of articulated energy sources, efficient energy utilization (electron beam and arc plasma), strong energy coupling to feedstock (electron beam and arc plasma), feedstock delivered directly to the melt pool, ability to deposit directly onto existing components, and potential to change chemical composition within a build to produce functionally graded materials. Feedstock for DED is delivered to the melt pool in coordination with the energy source, and the deposition head (typically) indexes up from the build surface with each successive layer.
5.3 Although DED systems can be used to apply a surface cladding, such use does not fit the current definition of AM. Cladding consists of applying a uniform buildup of material on a surface. To be considered AM, a computer aided design (CAD) file of the build features is converted into section cuts representing each layer of material to be deposited. The DED machine then builds up material, layer-by-layer, so material is only applied where required to produce a part, add a feature or make a repair.
5.4 DED has the ability to produce relatively large parts requiring minimal tooling and relatively little secondary processing. In addition, DED processes can be used to produce components with composition gradients, or hybrid structures consisting of multiple materials having different compositions and structures. DED processes are also commonly used for component repair and feature addition.
5.5 Fig. 1 gives a general guide as to the relative capabilities of the main DED processes compared to others currently used for meta...
SCOPE
1.1 Directed Energy Deposition (DED) is used for repair, rapid prototyping and low volume part fabrication. This document is intended to serve as a guide for defining the technology application space and limits, DED system set-up considerations, machine operation, process documentation, work practices, and available system and process monitoring technologies.
1.2 DED is an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited.
1.3 DED Systems comprise multiple categories of machines using laser beam (LB), electron beam (EB), or arc plasma energy sources. Feedstock typically comprises either powder or wire. Deposition typically occurs either under inert gas (arc systems or laser) or in vacuum (EB systems). Although these are the predominant methods employed in practice, the use of other energy sources, feedstocks and atmospheres may also fall into this category.
1.4 The values stated in SI units are to be regarded as standard. All units of measure included in this guide are accepted for use with the SI.
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
General Information
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Standards Content (Sample)
This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: F3187 − 16 (Reapproved 2023)
Standard Guide for
Directed Energy Deposition of Metals
This standard is issued under the fixed designation F3187; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 2. Referenced Documents
2.1 The latest version of the specifications referenced below
1.1 Directed Energy Deposition (DED) is used for repair,
should be used, unless specifically referenced otherwise in the
rapid prototyping and low volume part fabrication. This
main document.
document is intended to serve as a guide for defining the
technology application space and limits, DED system set-up 2.2 ASTM Standards:
B214 Test Method for Sieve Analysis of Metal Powders
considerations, machine operation, process documentation,
C1145 Terminology of Advanced Ceramics
work practices, and available system and process monitoring
D6128 Test Method for Shear Testing of Bulk Solids Using
technologies.
the Jenike Shear Tester
1.2 DED is an additive manufacturing process in which
E11 Specification for Woven Wire Test Sieve Cloth and Test
focused thermal energy is used to fuse materials by melting as
Sieves
they are being deposited.
E1316 Terminology for Nondestructive Examinations
E1515 Test Method for Minimum Explosible Concentration
1.3 DED Systems comprise multiple categories of machines
of Combustible Dusts
using laser beam (LB), electron beam (EB), or arc plasma
F327 Practice for Sampling Gas Blow Down Systems and
energy sources. Feedstock typically comprises either powder
Components for Particulate Contamination by Automatic
or wire. Deposition typically occurs either under inert gas (arc
Particle Monitor Method
systems or laser) or in vacuum (EB systems). Although these
F2971 Practice for Reporting Data for Test Specimens Pre-
are the predominant methods employed in practice, the use of
pared by Additive Manufacturing
other energy sources, feedstocks and atmospheres may also fall
2.3 ISO/ASTM Standards:
into this category.
52900 Additive Manufacturing—General Principles—
1.4 The values stated in SI units are to be regarded as Terminology
standard. All units of measure included in this guide are 52921 Standard Terminology for Additive Manufacturing—
Coordinate Systems and Test Methodologies
accepted for use with the SI.
2.4 ASQ Standard
1.5 This standard does not purport to address all of the
ASQ C-1 Specification of General Requirement For A Qual-
safety concerns, if any, associated with its use. It is the
ity Program
responsibility of the user of this standard to establish appro-
2.5 AWS Standards:
priate safety, health, and environmental practices and deter-
A3.0/A3.0M Standard Welding Terms and Definitions
mine the applicability of regulatory limitations prior to use.
A5.01/A5.01M Procurement Guidelines for Consumables—
1.6 This international standard was developed in accor-
Welding and Allied Processes
dance with internationally recognized principles on standard-
A5.02/A5.02M Specification for Filler Metal—Standard
ization established in the Decision on Principles for the
Sizes Packaging and Physical Attributes
Development of International Standards, Guides and Recom-
mendations issued by the World Trade Organization Technical
Barriers to Trade (TBT) Committee.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
1 3
This guide is under the jurisdiction of ASTM Committee F42 on Additive Available from American National Standards Institute (ANSI), 25 W. 43rd St.,
Manufacturing Technologies and is the direct responsibility of Subcommittee 4th Floor, New York, NY 10036, http://www.ansi.org.
F42.05 on Materials and Processes. Available from American Society for Quality, P.O. Box 3005, Milwaukee, WI
Current edition approved Dec. 15, 2023. Published January 2024. Originally 53201-3005.
approved in 2016. Last previous edition approved in 2016 as F3187 – 16. DOI: Available from American Welding Society (AWS), 8669 NW 36 St., #130,
10.1520/F3187-16R23. Miami, FL 33166-6672, http://www.aws.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F3187 − 16 (2023)
A5.14/A5.14M Specification for Nickel and Nickel-Alloy 3.2.4.1 Discussion—Arc processes suitable for DED are
Bare Welding Electrodes and Rods based ostensibly on the gas shielded processes, namely GTA,
A5.16/A5.16M Specification for Titanium and Titanium- PA, PTA, and GMA, and variants thereof.
Alloy Welding Electrodes and Rods
3.2.5 as built, adj—see as built, ISO 52900, and 3.3.
2.6 DIN Standard:
3.2.6 build platform, n—see build platform. ISO/ASTM
DIN 4188 Screening Surfaces; Wire Screens for Test Sieves,
Dimensions
3.2.6.1 Discussion—In ISO/ASTM 52900, the build plat-
2.7 ISO Standards:
form of a machine is defined as the base which provides a
ISO 9001 Quality Management Systems: Requirements
surface upon which the building of the part/s is started and
ISO 6983-2 Numerical control of machines – Program
supported throughout the build process. In DED, the build
format and definition of address words – Part 1: Data
platform can also be a component that is to be repaired, and
format for positioning, line motion and contouring control
may also be non-planar.
systems
3.2.7 capture effıciency, n—fraction of powder ejected from
ISO 565:1990 Test sieves – Metal wire cloth, perforated
the deposition head that is incorporated into the built structure.
metal plate and electroformed sheet -- Nominal sizes of
Usually expressed in percent.
openings
3.2.8 carrier gas, n—gas, typically inert, used to transport
2.8 NFPA Standard:
the powder from the deposition head to the melt pool and also
NFPA 484 Standard for Combustible Metals
in some systems to assist the transport of powder from the
2.9 OSHA Standards:
storage system to the deposition head.
CFR Title 29, Chapter XVII, Part 1910 Occupational Safety
3.2.9 cast, n—of a wire, diameter of the circle formed by a
and Health Standards
length of wire thrown loosely on the floor.
OSHA Standards Checklist: Volume 15 Welding, Cutting
3.2.10 cladding, n—see cladding, AWS A3.0/A3.0M.
and Brazing
3.2.11 cross stream, n—flow, normally of inert gas, directed
3. Terminology
perpendicular to the optical axis of the lens being protected.
3.1 DED Technology draws its terminology from several
3.2.12 cycle, n—single cycle in which one or more
sources, particularly from the 3D printing and welding indus-
components, features or repairs are built up in layers in the
tries. Section 3.2 lists the terminology used in this guide, with
build space of the machine. ISO/ASTM 52900
many definitions referring simply to other standards issued by
3.2.12.1 Discussion—DED is well suited to repair, feature
ASTM, ISO or AWS. Section 3.3 is then provided for the
addition and remanufacturing applications. Throughout this
reader’s convenience, re-listing some of the definitions most
guide, the use of the terms “DED Build Cycle” and “DED
important to an understanding of DED so the reader of this
Deposition Cycle” are synonymous, irrespective of whether a
guide does not have to cross-reference numerous other sources
complete part is built, or a portion thereof, or a repair.
of information simply be able to read this guide. Please note,
3.2.13 defect, n—see defect, Terminology E1316.
however, that the definitions given in 3.3 are NOT kept
3.2.14 deposition head, n—the device that delivers the
up-to-date as the official definitions of these terms. The reader
energy and feedstock to the melt pool.
needing the most up-to-date definition should reference the
3.2.15 deposition rate, n—see deposition rate, AWS A3.0/
other sources listed.
A3.0M.
3.2 Definitions of Terms Specific to This Standard:
3.2.16 directed energy deposition (DED), n—see ISO/
3.2.1 active gases, n—gases, including those containing
ASTM 52900 and 3.3.
carbon dioxide, oxygen, hydrogen and, in some cases, nitro-
gen. Most of these gases, which in large quantities, would
3.2.17 feed, n—a mechanism which delivers material, in the
damage the deposit, when used in small, controlled quantities,
form of wire or powder, to the melt pool.
can improve deposit characteristics.
3.2.18 filler metal, n—see filler metal, AWS A3.0/A3.0M.
3.2.2 agglomerates, n—cluster of primary particles held
3.2.19 flaw, n—see flaw, Terminology E1316.
together by weak physical interactions.
3.2.20 focal spot, n—see focal spot, AWS A3.0/A3.0M.
3.2.3 alloy, n—see alloy, AWS A3.0/A3.0M.
3.2.21 functionally graded material, n—depostied material
3.2.4 arc plasma, n—an ionized gas, used in all arc welding
that varies spatially in composition or structure, or both,
process, through which an electric current flows.
resulting in corresponding changes in the properties of the
material.
3.2.22 gas metal arc (GMA), n—see gas metal arc welding
Available from International Organization for Standardization (ISO), ISO
(GMAW), AWS A3.0/A3.0M.
Central Secretariat, BIBC II, Chemin de Blandonnet 8, CP 401, 1214 Vernier,
Geneva, Switzerland, http://www.iso.org.
3.2.22.1 Discussion—The word “welding” in the AWS defi-
Available from National Fire Protection Association (NFPA), 1 Batterymarch
nition conveys the joining of two or more pieces of material.
Park, Quincy, MA 02169-7471, http://www.nfpa.org.
As this is not the case for DED, the word “welding” is dropped.
Available from National Safety Council (NSC), 1121 Spring Lake Dr., Itasca,
IL 60143-3201, http://www.nsc.org. The remaining term characterizes the arc physics.
F3187 − 16 (2023)
3.2.23 gas porosity, n—property, presence of small voids in 3.2.36 manufacturing lot, n—see ISO/ASTM 52900.
a part making it less than fully dense.
3.2.37 manufacturing plan, n—a document that the pur-
chaser may require in order to control the quality and repeat-
3.2.23.1 Discussion—gas-filled flaws can form during the
ability of a deposition. A plan includes, but is not limited to the
DED process or subsequent post-processing that remain in the
production sequence, machine parameters, manufacturing con-
metal after it has cooled. This occurs because most liquid
trol system used in the production run, and quality checks.
materials can hold a large amount of dissolved gas, but the
3.2.37.1 Discussion—Manufacturing plans are typically re-
solid form of the same material cannot, so the gas forms flaws
quired under a quality management system such as ISO-9001
within the material as it cools. Gas porosity may present itself
and ASQ C-1.
on the surface of the DED deposit or the flaw may be trapped
inside the metal, which reduces strength in that vicinity.
3.2.38 melt pool, n—the region of material melted by the
3.2.24 gas tungsten arc (GTA), n—see gas tungsten arc
heat source.
welding (GTAW), AWS A3.0/A3.0M.
3.2.39 minimum explosible concentration (MEC), n—the
3.2.24.1 Discussion—See Discussion in 3.2.22.
minimum concentration of a combustible dust cloud that is
3.2.25 glovebox, n—typically a hermetically-sealed build
capable of propagating a deflagration through a well dispersed
space or chamber, normally filled with an inert gas, within
mixture of the dust and air under the specified conditions of
which material processing may occur. The chamber usually
test. E1515
includes gloves, through which an operator may reach to
3.2.40 mixed powder, n—powder composed of two or more
manipulate components within the chamber without breaking
constituent powders of different compositions.
the seal, hence the name.
3.2.40.1 Discussion—The DED process allows both the use
3.2.26 hatch spacing, n—the lateral distance between
of powders mixed prior to the start of the deposition and also
subsequent, adjacent passes of the deposition head whilst
mixing of powders enroute to the deposition head during the
depositing a layer.
deposition.
3.2.27 heat, n—see definition for powder lot per ISO/ASTM
3.2.41 near net shape, n—condition where the components
52900.
require little post processing to meet dimensional tolerance.
3.2.28 helix, n—of a wire, the vertical distance between one
3.2.42 plasma arc (PA), n—see plasma arc welding (PAW),
end of a wire and the other end formed by a length of spooled
AWS A3.0/A3.0M.
wire thrown loosely on the floor. Helix can also be referred to
3.2.42.1 Discussion—See Discussion in 3.2.22.
as “pitch”.
3.2.43 plasma transferred arc (PTA), n—Plasma Trans-
3.2.29 hopper, n—the converging portion of a bin. D6128
ferred Arc (PTA) is a constricted arc process similar to Plasma
3.2.30 inert gas, n—see inert gas AWS, A3.0/A3.0M.
Arc Welding (PAW) in most respects. The arc is constricted
using a water-cooled small diameter nozzle which reduces the
3.2.31 intermetallic phases, n—compounds, or intermediate
arc diameter and increases its power density. PTA differs from
solid solutions, containing two or more elements, which
PAW inasmuch as it is used predominantly as a surfacing
usually have characteristic properties and crystal structures
process rather than a joining process. PTA also usually uses
different from those of the pure metals or the terminal solid
powder feed delivery (through powder ports in the nozzle or an
solutions. E7
annular feed around the nozzle) so is more flexible in terms of
3.2.32 interpass temperature, n—see interpass temperature,
the alloys that can be deposited, since more alloys tend to be
AWS A3.0/A3.0M.
commercially available in powder form than in wire form.
3.2.33 interpass time, n—the length of time between ending
3.2.44 powder blend, n—quantity of powder made by thor-
a particular layer and starting the next layer, or the length of
oughly intermingling powders originating from one or several
time between individual beads.
powder lots of the same nominal composition.
3.2.33.1 Discussion—Further to the AWS definition, in
3.2.44.1 Discussion—A common type of powder blend
DED a common practice is to deposit multiple adjacent
consists of a combination of virgin and used powder. The
deposition beads in succession (as when following a hatch
specific requirements for a powder blend are typically deter-
pattern on a layer), and then allow the entire layer to cool
mined by the application, or by agreement between the supplier
before commencing the next layer. When this term i
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