SOURCE: IDRW.ORG
The Indian Institute of Technology Kharagpur (IIT Kharagpur), a premier engineering institution, is making a transformative investment in Directed Energy Deposition (DED) based additive manufacturing, a cutting-edge technology poised to redefine manufacturing processes. This strategic move promises to cultivate a new generation of material scientists whose innovations could galvanize the aerospace and medical industries. Once mastered, DED’s unique capabilities could position India as a leader in advanced manufacturing, driving breakthroughs in precision engineering and custom fabrication.
Directed Energy Deposition is an additive manufacturing technique that uses a focused energy source—typically a laser or electron beam—to melt and deposit material, layer by layer, directly onto a substrate or existing component. Unlike traditional subtractive manufacturing, which carves parts from solid blocks, or powder bed fusion methods like Selective Laser Melting (SLM), DED excels in its ability to build, repair, or clad large-scale metal structures with high precision. Materials such as titanium, aluminum, and nickel alloys, critical to aerospace and medical applications, are fed as powder or wire, melted in real-time, and fused to create complex geometries.
IIT Kharagpur’s focus on DED aligns with its Centre of Excellence in Advanced Manufacturing Technology, established with support from the Department of Heavy Industry and industry giants like Tata Steel and BHEL. This initiative builds on the institute’s legacy of interdisciplinary research, merging metallurgy, mechanical engineering, and materials science to push the boundaries of what’s possible in additive manufacturing.
In the aerospace sector, DED’s utility is transformative. Aircraft components, such as turbine blades, engine casings, and structural supports, demand lightweight yet durable materials that withstand extreme temperatures and stresses. DED enables the creation of these parts with near-net-shape precision, minimizing material waste—a stark contrast to traditional methods where up to 90% of raw material can be discarded. For instance, titanium alloys, widely used in jet engines, can be deposited layer-by-layer to form intricate designs that optimize strength-to-weight ratios, a critical factor in fuel efficiency and performance.
Beyond fabrication, DED’s ability to repair high-value components is a game-changer. Instead of replacing a damaged turbine blade, DED can deposit material to restore its shape and functionality, extending service life and slashing costs—a boon for the Indian Air Force and commercial airlines alike.
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