A Coupled Approach To Weld Pool, Phase And Residual Stress Modelling Of Laser Direct Metal Deposition (LDMD) Processes

M. Vogel, M. Khan, J. Ibara-Medina, A. Pinkerton, N. N’Dri and M. Megahed, A Coupled Approach to Weld Pool, Phase and Residual Stress Modelling of Laser Direct Metal Deposition (LDMD) Processes, 2nd World Congress on Integrated Computational Materials Engineering, July 7-11, Salt Lake City, USA, Proceedings ISBN 978-1-11876-689-7, pp. 231-236, 2013. 10.1002/9781118767061.ch37.

This paper describes a complete CFD model of the laser metal deposition process. The model covers the complete process, starting from the simulation of powder particles in the deposition head and finishing with the final part. Individual phenomena that are considered in the gas-phase stage of the model include the ricocheting of particles within the head, the flow of powder particles, their interaction with the laser and powder catchment/bouncing. Phenomena considered in the liquid phase (melt pool) stage of the model include particle enthalpy effects, buoyancy, temperature-dependent material properties and Marangoni forces. The CFD model is coupled with a metallurgical database to predict the phase and material properties of the solidified deposit and heat affected area and residual stresses in the part. Modelled and experimental characteristics of multi-track deposits of M2 steel show good agreement.

Michael Vogel, Mushtaq Khan, Juansethi Ibara-Medina - Manufacturing and Management Group, School of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Sackville Street, Manchester M13 9PL, United Kingdom