Directed energy deposition of molybdenum

Two directed energy deposition processes were evaluated for additive manufacturing of molybdenum. First, a laser-based process was used to deposit plasma spheroidized molybdenum powder. The effects of laser power, substrate temperature, and substrate composition on deposition quality were explored. Second, an electron beam-based process was used to deposit molybdenum wire on molybdenum substrates at two deposition rates. Depositions up to 100 mm wide by 500 mm long with minimal porosity and cracking were produced, but residual stress resulted in significant distortion of the substrates for a thickness of 12 mm.