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Directed Energy Deposition (DED) processes offer one of the most versatilecurrent techniques to additively manufacture and repair metallic componentsthat have generatively designed complex geometries, and with compositionalcontrol. When compared to powder bed fusion (PBF), its applicability andadoption has been limited because several issues innate to the process are yetto be suitably understood and resolved. This work catalogs and delineates theseissues and anomalies in the DED process along with their causes and solutions,based on a state-of-the-art literature review. This work also serves toenumerate and associate the underlying causes to the detrimental effects whichmanifest as undesirable part/process outcomes. These DED-specific anomalies arecategorized under groups related to the part, process, material, productivity,safety, repair, and functional gradients. Altogether, this primer acts as aguide to best prepare for and mitigate the problems that are encountered inDED, and also to lay the groundwork to inspire novel solutions to furtheradvance DED into mainstream manufacturing.

A Review of the Anomalies in Directed Energy Deposition (DED) Processes and Potential Solutions