In order to improve the process efficiency of a direct energy deposition (DED) system, closed loop control systems can be considered for monitoring the deposition and melting processes and adjusting the process parameters in real-time. In this paper, the monitoring of a new deposition nozzle solution for DED systems is approached through a simulation-experimental comparison. The shape of the powder flow at the exit of the nozzle outlet and the spread of the powder particles on the deposition plane are analyzed through 2D images of the powder flow obtained by monitoring the powder depositions with a high-speed camera. These experimental results are then compared with data obtained through a Computational Fluid Dynamics model. Preliminary tests are carried out by varying powder, carrier, and shielding mass flow, demonstrating that the last parameter has a significant influence on the powder distribution and powder flow geometry.

In order to improve the process efficiency of a DED system, closed loop control systems can be considered, monitoring the deposition and melting processes and adjusting the process parameters in real-time. In this paper, the monitoring of a new deposition nozzle solution for DED systems was approached through a simulation-experimental comparison. The shape of the powder flow at the exit of the nozzle outlet and the spread of the powder particles on the deposition plane were analyzed through 2D images of the powder flow obtained monitoring the powder depositions with a high-speed camera. These experimental results were then compared with data obtained through a numerical CFD model. Preliminary tests were carried out by varying powder, Carrier and Shielding mass flow, demonstrating that the last parameter has a significant influence on the powder distribution and powder flow geometry.