Fabrication method for stainless steel foam block in directed energy deposition

Abstract Using powder-based directed energy deposition (DED), composite materials can easily be produced by mixing powders. In this study, a foam stainless block is fabricated through DED by combining SUS316L and titanium-hydride (TiH2) powders together. Although TiH2 successfully foams the melt pool and leaves many pores inside the deposit, it is difficult to enhance the porosity rate because the porous structure is destroyed when the upper layer is deposited. This study demonstrates a laser power control and deposition trajectory that can be used to create a low-density porous structure and measures the compression strength of the fabricated block.