Dataset of AISI 316L melt track dimensions, powder catchment efficiency, and particle stream measurements for laser beam directed energy deposition

OVERVIEW OF DATASET This data repository documents the characterization of AISI 316L single melt tracks and the corresponding particle stream diameters and particle velocity distributions during powder blown laser beam directed energy deposition (DED-LB) additive manufacturing. The melt track powder catchment efficiency was measured across variations of powder diameter, carrier gas flow rate, and laser parameters (spot diameter and power). The diameter of the particle stream and the particle velocity were measured using high-speed imaging and image processing. Melt track volumetric dimensions were measured using optical profilometry. The goal of this repository is to provide a process-to-structure dataset to evaluate powder catchment efficiency and melt track height prediction models in the DED-LB community. In addition, this repository provides an experimental dataset of particle-laden flow morphology with Stokes numbers ranging between approximately 40 to 4,000 for a discrete three-jet coaxial nozzle. DATA & FILE OVERVIEW Directory of Files: A. Filename: DED316L_TrackResultSummaryDF.xlsx Short description: This Excel sheet contains all experimental data organized into a labeled data frame for data analysis. Tracks were deposited under factorial combinations of powder diameter (21-35, 67-80, and 80-106 μm), carrier gas flow rate (2, 4, 6, 8, and 10 L/min), and laser spot diameter (1.5, 2.5, and 3.5 mm). B. Filename: ParticleStreamDistribution.zip Short description: This folder contains spatial distribution images of the particle stream from the three-jet DED-LB nozzle using nine total combinations of powder diameters (21-35, 67-80, and 80-106 μm) and carrier gas flow rates (2, 6, and 10 L/min). Each imaging was performed at 14,400 Hz using an exposure of 1.99 μs for a 1-second total duration. C. Filename: DED316L_ParticleVelocity_n1000.xlsx Short description: This Excel sheet contains the particle velocities measured between 0-5mm below the nozzle exit under nine total combinations of powder diameters (21-35, 67-80, and 80-106 μm) and carrier gas flow rates (2, 6, and 10 L/min). Each imaging was performed at 20,000 Hz using an exposure of 1.99 μs for a 1-second total duration, with particle tracking performed using the TrackMate software within ImageJ-FIJI. D. Filename: ParticleVelocity_300fVideoClips.zip Short description: This folder contains 300-frame example clips of the high-speed imaging used to record the particle velocities in file 'DED316L_ParticleVelocity_n1000.xlsx'. Each imaging was performed at 20,000 Hz using an exposure of 1.99 μs for a 1-second total duration, with particle trajectories visualized using the TrackMate software within ImageJ-FIJI. E. Filename: Powder316L_SEM.zip Short description: This folder contains scanning electron microscopy of the three 316L gas-atomized powder batches (21-35, 67-80, and 80-106 μm) used for deposition. F. Filename: TrackOpticalProfilometry.zip Short description: This folder contains optical and volumetric height maps of the 45 deposited AISI 316L single melt tracks, each 60 mm in length, measured using optical profilometry. The tracks were deposited under factorial combinations of powder diameter (21-35, 67-80, and 80-106 μm), carrier gas flow rate (2, 4, 6, 8, and 10 L/min), and laser spot diameter (1.5, 2.5, and 3.5 mm) G. Filename: HighSpeedDataForGitLabCode.zip Short description: This folder contains 14,400 raw high-speed image frames of one particle stream using the 67 - 80 um powder under a carrier gas flow rate of 6 L/min. These files are intended for use with the released image processing code, available in the "Code availability" portion of the main manuscript.