Additive manufacturing of nickel spring using laser wire directed energy deposition process

Abstract

This thesis presents the successful completion of additive manufacturing of a helical nickel spring using the laser wire directed energy deposition (LW-DED) process. A systematic analysis was performed to find the suitable range of process parameters, such as wire feed rate, laser power, and rotation speed, to achieve continuous and sound deposition. Critical aspects like effect of each process parameters, alignment orientation, cooling strategy were studied for their effects on deposition quality. Post-deposition, mechanical separation techniques were employed to extract the spring. Post separation, mechanical tests were performed to evaluate properties of the spring. Challenges such as non-uniform pitch and wire path deviation were analysed, and appropriate corrective measures were implemented. This research contributes to expanding the applicability of LW-DED in fabricating customised, near-net-shaped spring geometries, offering potential use cases in aerospace, robotics, and medical applications.