Effect of Ultrasonic Assistance in Laser-Based Directed Energy Deposition (DED) Process: A Review

Abstract:

In this present work, a newly emerging manufacturing process, namely metal additive manufacturing, is discussed in detail. The review work considers articles that describe the impact of ultrasonic vibration assistance on the laser-based Directed Energy Deposition (LP-DED) process, a promising approach in metal additive manufacturing. The incorporation of high-frequency ultrasonic vibrations during deposition enhances melt pool dynamics, promotes refined grain structures, and significantly reduces the formation of porosity and residual stress. Ultrasonic-assisted DED contributes to improved interlayer bonding, uniform particle dispersion, and enhanced mechanical properties of the printed part. Results indicate that this hybrid approach can optimise deposition quality and mechanical performance, making it suitable for critical applications across aerospace, biomedical, and energy sectors. The findings highlight ultrasonic assistance as a valuable tool for overcoming key challenges in conventional DED processes.

• Periodical: Key Engineering Materials (Volume 1058)
• Pages: 101-109
• DOI: https://doi.org/10.4028/p-8l6cbF
• Online since: June 2026
• Authors: Chundi Sukumar*, Chandan Kumar, Manjesh Kumar, Sujit Das
• Keywords: Directed Energy Deposition, Metal 3D Printing, Microstructure, Ultrasonic Vibration

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