Effect of Microgravity on the Metal Droplet Transfer and Bead Characteristics in the Directed Energy Deposition-Arc Process

Directed energy deposition-arc (DED-arc) is a viable method of metal 3D printing for manufacturing in-space under microgravity conditions. This study investigates the effect of reduced gravity on the droplet transfer in a gas metal arc welding (GMAW)-based DED-arc process. Single bead deposited using GMAW welding process under microgravity and standard terrestrial gravity (1 g) are compared. Microgravity was simulated in a drop tower where the experimental capsule was subjected to 2.5 s of free-fall. The experimental setup for GMAW welding process, including high-speed cameras and sensors, was present within the experimental capsule. Droplet frequency and diameter were measured and compared between microgravity and 1 g using the images obtained. Further, the impact of reduced gravity on weld bead geometry and the distribution of gas porosity was investigated. Microhardness analysis was also conducted on both 1 g and reduced gravity samples to assess variations in material hardness. A statistically significant difference in droplet diameter and frequency was found. This difference is attributed to the reduction in gravitational force. Upon analyzing the weld bead geometry, noticeable variations are detected in the contact angles and the reinforcement of beads formed under different gravity conditions. These differences are attributed to alterations in convection within the molten weld pool. The blowhole analysis revealed a noticeable trend, wherein reduced gravity facilitated the coalescence of gas porosity, resulting in larger diameters due to alterations in weld pool convection. There were no statistically significant changes observed in both microhardness and surface finish.