Influence of Induced Energy on the Characteristics of Hybrid and Non-hybrid DED of Low Carbon Steel

Abstract

The application of induced energy in additive manufacturing (AM) offers several advantages as well as certain limitations. A comparative experimental study was conducted to investigate the influence of induced energy on the effectiveness of various AM processes using a common set of process parameters. The primary objective was to identify the most efficient wire arc-based AM process among Metal Inert Gas (MIG), Tungsten Inert Gas (TIG), Laser Wire, and their hybrid combinations (MIG-TIG, Laser-MIG, and Laser-TIG) with respect to energy utilization, process dynamics (cooling rate), bead geometry (height and width), and material properties (hardness) under varying power inputs. The results revealed that the specific energy consumption increased with increasing power input for all the processes. Bead hardness increased with higher cooling rates and greater bead height from the substrate plate. Statistical analyses were performed to assess measurement repeatability and determine the influence of input power on process outputs. The effects of power input, the advantages of hybrid AM processes, and the selection of suitable AM processes for desired outputs were evaluated using radar chart analysis. Energy Dispersive X-ray Spectroscopy (EDS) revealed variations in the weight percentage, concentration, and distribution of elements across the bead cross-sections. Microstructural analysis showed the presence of acicular ferrite, which enhances toughness and improves resistance to crack propagation. The formation of upper bainite facilitates carbon partitioning prior to its precipitation in ferrite, while the presence of cementite (Fe₃C) in the deposited material contributes to increased strength of the steel. © The Institution of Engineers (India) 2026.