Dataset of process parameters, melt track geometry, powder catchment, and particle stream measurements for the laser beam directed energy deposition of AISI 316L.

This dataset reports the characterization and data processing methodology of 45 individual AISI 316L single melt tracks, fabricated by powder blown laser beam directed energy deposition (DED-LB) metal additive manufacturing. The melt tracks were deposited across a parametric combination of process parameters: powder size distributions, carrier gas flow rates, and laser spot diameter-laser power sets. The measured melt track properties include the average melt track width, height, cross-sectional area, and the powder catchment efficiency. Optical profilometry was used to extract the melt track dimensions and to calculate the powder catchment efficiency. In addition, the corresponding particle stream spatial distributions and particle velocity distributions were measured across the deposition flow parameters by processing high-speed image data. The median particle Stokes number for each flow condition was reported for comparability with other discrete coaxial nozzle systems with particle-laden flows. This dataset can aid in the validation of computational simulations of particle-laden flows from three-jet nozzle systems and the validation of DED-LB models which predict the melt track properties from known process parameters.