Generation and Suppression of Pendant Droplet Oscillation in Electron Beam Directed Energy Deposition

Electron beam–directed energy deposition (EB–DED) has emerged as a promising wire-based metal additive manufacturing technique. However, the effects of EBs on pendant droplets at wire tips have not yet been determined. The aim of this study is to enhance the understanding of this action by analyzing the mechanism of droplet oscillation. The pendant droplet oscillation phenomenon hinders the stable transfer of droplets to the molten pool and limits the feasibility of manufacturing complex lattice structures by EB–DED. Hence, another aim of this study is to create an oscillation suppression method. An escalating asymmetric amplitude is the main characteristic of droplet oscillation. The primary oscillation-inducing force is the recoil force generated from the EB-acted local surface of the droplet. The physical mechanism of this force is the rapid increase and uneven distribution of the local surface temperature caused by the partial action of the EB. The prerequisites for droplet oscillation include vacuum conditions, high power densities, and bypass wire feeding processes. The proposed EB–dynamic surrounding melting (DSM) method can be applied to conveniently and effectively suppress oscillations, enable the accurate transfer of droplets to the molten pool, and achieve stable processes for preparing the strut elements of lattice structures. Lowering the temperature and improving the uniformity of its distribution are the mechanisms of oscillation suppression in EB–DSM. In this study, the physical basis for interpreting the mechanism by which EBs act on droplets and the technical basis for using EB–DED to prepare complex lattice structure parts are provided.