This study examines the porosity behavior during the directed energy deposition (DED) of dissimilar metals S45C and H13. We analyzed the effects of deposition parameters, including laser power, feed rate, and powder characteristics, on pore formation, taking into account the unique properties of these metals. Our findings indicate that laser power is the primary factor influencing porosity. At a low power of 200 W, insufficient energy input, along with differences in thermal conductivity and chemical composition between S45C and H13, led to incomplete melting and lack-of-fusion, resulting in high porosity. As the laser power increased to 400-600 W, the melt pool stabilized, enhancing interfacial bonding and significantly reducing porosity. However, at an excessive power of 800 W, rapid melting and solidification of the powder caused gas entrapment and pore formation, which increased porosity, particularly due to the differing thermal conductivities of S45C and H13. Therefore, our results suggest that maintaining an adequate laser power of 400-600 W is essential for achieving a stable melt pool and minimizing porosity in the DED process for dissimilar S45C and H13 metals.
