Numerical Simulation of the Thermal History Multiple Laser Deposited Layers

Abstract

Multilayer direct laser metal deposition is a fabrication process in which the parts are fabricated by creating a molten pool into which metal powder particles are injected, and a layer is laid down by moving the pool. Height is added by creating additional layers on top of the first layer. During fabrication, a complex thermal history is experienced in different regions of the build. The thermal history includes the reheating process for previously deposited layers caused by subsequently deposited layers. The objective of this study is to provide insight into the thermal history during the direct laser deposition process. Using the commercial ABAQUS/CAE software, a thermomechanical 3D finite element model was developed. This work presents a 3D heat transfer model that considers the continuous addition of powder particles in the front of a moving laser beam using ABAQUS/CAE software. The model assumes the deposit geometry appropriate to each experimental condition and calculates temperature distribution, cooling rates, and remelted layer depth which can affect the final microstructure. Model simulations were qualitatively compared with experiments results acquired in situ using a K-type thermocouple.

Department(s)

Materials Science and Engineering

Second Department

Mechanical and Aerospace Engineering

Keywords and Phrases

Computer Simulation; Fabrication; Finite Element Method; Heat Transfer; Powder Metals; Spot Welding; Thermocouples; 3D Finite Element Model; Direct Laser Deposition; Experimental Conditions; Fabrication Process; Final Microstructures; Heat Transfer Model; K-Type Thermocouples; Laser Metal Deposition; Deposition; 3D Finite Element Modeling; Direct Laser Deposition Process; Heat Transfer

International Standard Serial Number (ISSN)

0268-3768

Document Type

Article - Journal

Document Version

Citation

File Type

text

Language(s)

English

Rights

© 2014 Springer Verlag, All rights reserved.

Publication Date

01 Aug 2014

Link to Full Text

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