This article presents a detailed account of directed-energy deposition (DED) processes that are used for additive manufacturing (AM) of metallic materials. It begins with a process overview and a description of the components of DED systems followed by sections providing information on the process involved in DED and the materials used for DED. The postprocessing applied to the material after deposition is then covered. The article discusses the properties of metallic materials produced by using DED and ends with a discussion on applications for DED processes in various industries.

Directed-energy deposition (DED) is a kind of additive manufacturing (AM) technology based on synchronous powder feeding or wire feeding. This article provides a comprehensive coverage of DED for ceramic AM, beginning with an overview of DED equipment setup, followed by a discussion on DED materials and the DED deposition process. The bulk of the article is devoted to the discussion on the microstructure and properties of oxide ceramics, namely alumina and zirconia ceramics.

This article covers in-line process monitoring of the metal additive manufacturing (AM) methods of laser and electron beam (e-beam) powder-bed fusion (PBF) and directed-energy deposition (DED). It focuses on methods that monitor the component directly throughout the build process. This article is organized by the type of AM process and by the physics of the monitoring method. The discussion covers two types of monitoring possible with the PBF process: monitoring the area of the powder bed and component and monitoring the melt pool created by the laser or e-beam. Methods for layer monitoring include optical and thermal methods that monitor light reflected or emitted in the visible and infrared wavelengths, respectively. Monitoring methods for laser directed-energy deposition (DED) discussed are those that measure the size and shape of the melt pool, the temperature of the melt pool, and the plasma generated by the laser as it interacts with the molten metal.

This article focuses on the directed-energy deposition (DED) additive manufacturing (AM) technique of biomedical alloys. First, it provides an overview of the DED process. This is followed by a section describing the design and development of the multiphysics computational modeling of the layer-by-layer fusion-based DED process. A brief overview of the primary governing equations, boundary conditions, and numerical methods prescribed for modeling laser-based metal AM is then presented. Next, the article discusses fundamental concepts related to laser surface melting and laser-assisted bioceramic coatings/composites on implant surfaces, with particular examples related to biomedical magnesium and titanium alloys. It then provides a review of the processes involved in DED of biomedical stainless steels, Co-Cr-Mo alloys, and biomedical titanium alloys. Further, the article covers novel applications of DED for titanium-base biomedical implants. It concludes with a section on the forecast of DED in biomedical applications.