This $598,650 five-year National Science Foundation (NSF) Engineering program grant, awarded on August 1, 2024, supports fundamental research by The Pennsylvania State University (Penn State) aimed at understanding the processing-structure-property relationships in metallic parts manufactured using a co-axial wire feed-powder feed laser directed energy deposition (DED) process. The research objectives are to: (1) compare deposit formations in the co-axial wire-powder DED process to singular wire and powder DED processes; (2) assess the evolution of melt pools and quantify microstructural characteristics; and (3) establish correlations between tensile strengthening mechanisms and varying wire-to-powder feed ratios. The resulting knowledge is expected to enable wider adoption of wire-based additive manufacturing, with the potential to fabricate large-scale parts for applications in power generation, propulsion, and space exploration at reduced cost and material waste. The project integrates educational and outreach activities to empower future engineers and scientists.
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