SIM-AM 2025

Additive Manufacturing Benchmark Test Series 2025: Laser Hot Wire Directed Energy Deposition Overview

  • Dantin, Matthew (NSWC, Carderock Division)
  • Levine, Lyle (NIST)

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The Additive Manufacturing Benchmark Test Series (AM-Bench) is a NIST-led organization that provides a continuing series of AM benchmark measurements, modeling challenge problems, and conferences with the primary goal of enabling modelers to test their simulations against rigorous, highly controlled additive manufacturing benchmark measurement data [1]. This presentation will detail the build design, measurement systems, modeling challenge problems, and a sampling of results associated with the laser hot-wire directed energy deposition (LHW-DED) benchmarks. The two sets of benchmarks that will be discussed are: (i) LHW-DED 3D builds of nickel-based super alloy 718 test objects and (ii) single bead thickness walls and individual single bead depositions with variations in processing parameters. Measurements and modeling challenge problems associated with this set of benchmarks include residual stress/strain, baseplate deflection upon unclamping, grain size distributions, baseplate temperatures during the build, and wire bead geometries. REFERENCES [1] https://www.nist.gov/ambench/short-descriptions-2025-benchmarks