In a collaboration between Meltio (Alejandro Martinez and Fran Carretero) and Ansys (Abel Ramos and Dr. Enrique Escobar de Obaldia), the accuracy of Ansys additive manufacturing simulation was evaluated. Using the AM-DED module in Ansys Additive Suite, the printability of a nickel-based turbine blade component was investigated and the results were compared with a physical part.

Directed energy deposition (DED), an additive manufacturing (AM) technology, is known for its varied usages that enable manufacturing and the repair of metal components using powder or wire material. While other technologies such as powder bed fusion limit the size of the printing components to the machine build envelopes, AM-DED (wire arc and laser-based wire) processes offer larger build envelopes, high deposition rates, greater cost benefits, and increased manufacturing freedom due to the multiple deposition axes. AM-DED is used today across multiple industries, including mass manufacturing, maintenance, and industrial applications. But despite these advantages, distortions and residual stresses can potentially be observed in printed components. Especially when manufacturing large metal components that can take days or weeks to complete, it is essential to control the process and avoid manufacturing defects.