Laser & Optoelectronics Progress, Volume. 61, Issue 21, 2114003(2024)

Thermal-Fluid Coupling Numerical Simulation Study of Temperature Field and Molten pool Morphology of Laser Direct Energy Deposition

Kaixiong Hu1,3, Feiyang Li1, Yong Zhou1, and Weidong Li2、*
Author Affiliations
  • 1School of Transportation and Logistics Engineering, Wuhan University of Technology, Wuhan 430063,Hubei ,China
  • 2School of Mechanical Engineering, University of Shanghai for Science and Technology, Shanghai 200093, China
  • 3Hubei Longzhong Laboratory, Xiangyang441022, Hubei , China
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    Figures & Tables(21)
    Schematic diagram of LDED
    Schematic of energy transfer and force analysis of the molten pool during LDED[9]
    Thermal property parameters of 316 L stainless steel. (a) Density; (b) thermal conductivity; (c) enthalpy; (d) specific heat capacity
    Thermal property parameters of Q235 steel. (a) Density; (b) thermal conductivity; (c) enthalpy; (d) specific heat capacity
    Geometric model and meshing
    Experimental platform of LDED
    Molten pool morphology validation. (a) Molten pool morphology measurement; (b) comparison of experimental (left) and simulated (right) molten pool morphology
    Temperature validation. (a) Temperature measurement points in simulation; (b) positions of the thermocouple in the experiment
    Comparison between experimental and simulated temperatures. (a) Point 1; (b) point 2
    Transverse cross-sectional temperature field distributions of molten pool under different laser powers. (a) 1000 W; (b) 1200 W; (c) 1400 W; (d) 1600 W
    Top view of molten pool temperature field under different scanning speeds. (a) 8 mm/s; (b) 10 mm/s; (c) 12 mm/s; (d) 14 mm/s
    Temperature variation over time at the midpoint for different scanning speeds
    Longitudinal cross-sectional temperature field distributions of the molten pool at different powder feeding rates. (a) 0.070 g/s; (b) 0.095 g/s; (c) 0.120 g/s; (d) 0.145 g/s
    Molten pool flow field distribution
    Influence of process parameters on the peak flow velocity of the molten pool
    Temperature variation over time at the midpoint of different tracks during multiple overlapping deposition
    Schematic illustration of the molten pool heat transfer. (a) Single symmetrical track; (b) single asymmetric track; (c) multiple track overlapping
    Transverse cross-sectional solid-liquid phase diagrams of molten pool in adjacent tracks during multiple overlapping deposition
    • Table 1. Main process parameters involved in the simulation model

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      Table 1. Main process parameters involved in the simulation model

      ParameterValue
      Spot radius /mm2.25
      Powder stream radius /mm1.5
      Powder capture efficiency0.6
      Absorption efficiency0.35
      Viscosity /(kg·m-1·s-10.007
      Volumetric expansion coefficient /K-15.85×10-5
      Surface tension coefficient /(N·m-1·K-1-0.4×10-3
    • Table 2. Orthogonal experimental design table

      View table

      Table 2. Orthogonal experimental design table

      LevelLaser power P /WScanning speed V /(mm·s-1Powder feeding rate F /(g·s-1
      1100080.070
      21200100.095
      31400120.120
      41600140.145
    • Table 3. Comparison of molten pool morphology dimensions

      View table

      Table 3. Comparison of molten pool morphology dimensions

      No.P /WV /(mm∙s-1F /(g∙s-1Width /mmHeight /mmDepth /mm
      ExperimentSimulationExperimentSimulationExperimentSimulation
      11200100.0952.4612.6050.3350.3420.3010.278
      21600140.0702.7202.6050.3000.2900.4550.420
      3140080.1202.7362.5900.6470.6110.4340.480
      4160080.1453.1643.3601.0050.9620.5840.577
      51000140.0952.1212.1300.1790.1950.0850.100
      61200120.1452.6062.5800.4280.4430.2630.290
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    Kaixiong Hu, Feiyang Li, Yong Zhou, Weidong Li. Thermal-Fluid Coupling Numerical Simulation Study of Temperature Field and Molten pool Morphology of Laser Direct Energy Deposition[J]. Laser & Optoelectronics Progress, 2024, 61(21): 2114003

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    Paper Information

    Category: Lasers and Laser Optics

    Received: Jan. 5, 2024

    Accepted: Feb. 23, 2024

    Published Online: Nov. 18, 2024

    The Author Email: Weidong Li (weidongli@usst.edu.cn)

    DOI:10.3788/LOP240455

    CSTR:32186.14.LOP240455

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