The process optimization of directed energy deposition (DED) has become imperative in the manufacture of reliable products. However, an energy-density-based approach without a sufficient powder feed rate hinders the attainment of an appropriate processing window for DED-processed materials. Optimizing the processing of DEDprocessed Ti-6Al- 4V alloys using energy per unit area (E_eff) and powder deposition density (PDD_eff) as parameters helps overcome this problem in the present work. The experimental results show a lack of fusion, complete melting, and overmelting regions, which can be differentiated using energy per unit mass as a measure. Moreover, the optimized processing window (E_eff = 44~47 J/mm² and PDD_eff = 0.002~0.0025 g/mm²) is located within the complete melting region. This result shows that the Eeff and PDDeff-based processing optimization methodology is effective for estimating the properties of DED-processed materials.

Powder quality, including high flowability and spherical shape, determines the properties of additively manufactured products. Therefore, the cheap production of high-quality powders is critical in additive manufacturing. Radio frequency plasma treatment is an effective method to fabricate spherical powders by melting the surface of irregularly shaped powders; in the present work, mechanically milled Zr powders are spheroidized by radio frequency plasma treatment and their properties are compared with those of commercial Zircaloy-2 alloy powder. Spherical Zr particles are successfully fabricated by plasma treatment, although their flowability and impurity contents are poorer than those of the commercial Zircaloy-2 alloy powder. This result shows that radio-frequency plasma treatment with mechanically milled powders requires further research and development for manufacturing low-cost powders for additive manufacturing.