STUDY OF THERMAL DISTRIBUTION AND CLADDING GEOMETRY DURING LASER METAL DEPOSITION PROCESS USING FINITE ELEMENT ANALYSIS
Keywords:
additive manufacturing, laser cladding, melt pool, heat transfer, cladding height, finite element
Abstract
The paper deals with additive manufacturing process for coating and 3D printing metallic materials known in literature as laser cladding, laser melting deposition, laser engineering net shaping or direct energy deposition. In this process a melt pool was generated at the interaction of the laser beam with the blown powder guided through a copper nozzle. A 3D finite element model was established to simulate laser cladding process taking into account heat transfer in solids and geometry deformation modules from COMSOL Multiphysics software. A time-dependent study was conducted to manage the computational time of the numerical model. Boundary conditions were established by introducing a Gaussian distribution for the laser energy, as well as for the velocity and shape of the resulting track. Additionally, the thermal properties of the material under investigation were taken into account. Thermal analysis was conducted to determine the temperature history during the process using a heat transfer module, while the dynamic shape of the molten zone was represented by a moving mesh based on a deformed geometry module.
References
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2. S. Mihai, F. Baciu, R. Radu, D. Chioibasu, and A. C. Popescu, “In Situ Fabrication of TiC/Ti–Matrix Composites by Laser Directed Energy Deposition,” Materials 2024, Vol. 17, Page 4284, vol. 17, no. 17, p. 4284, Aug. 2024.
3. L. Duta et al., “In Vivo Assessment of Bone Enhancement in the Case of 3D-Printed Implants Functionalized with Lithium-Doped Biological-Derived Hydroxyapatite Coatings: A Preliminary Study on Rabbits,” Coatings 2020, Vol. 10, Page 992, vol. 10, no. 10, p. 992, Oct. 2020.
4. M. Izadi, A. Farzaneh, M. Mohammed, I. Gibson, and B. Rolfe, “A review of laser engineered net shaping (LENS) build and process parameters of metallic parts,” Rapid Prototyp J, vol. 26, no. 6, pp. 1059–1078, Jun. 2020.
5. S. Mihai, P.-V. Toma, A. Sima, D. Chioibasu, and A. C. Popescu, “A novel method of nondestructive characterization via X-ray and high-speed imaging of TiC/IN718 composite materials manufactured by LMD,” Results in Engineering, vol. 24, p. 103350, Dec. 2024.
6. D. Chioibasu, S. Mihai, C. M. Cotrut, I. Voiculescu, and A. C. Popescu, “Tribology and corrosion behavior of gray cast iron brake discs coated with Inconel 718 by direct energy deposition,” International Journal of Advanced Manufacturing Technology, vol. 121, no. 7–8, pp. 5091–5107, Aug. 2022.
7. S. Mihai, D. Chioibasu, M. A. Mahmood, L. Duta, M. Leparoux, and A. C. Popescu, “Real-Time Defects Analyses Using High-Speed Imaging during Aluminum Magnesium Alloy Laser Welding,” Metals 2021, Vol. 11, Page 1877, vol. 11, no. 11, p. 1877, Nov. 2021.
8. G. Meng, Y. Gong, J. Zhang, L. Zhu, H. Xie, and J. Zhao, “Multi-scale simulation of microstructure evolution during direct laser deposition of Inconel718,” Int J Heat Mass Transf, vol. 191, p. 122798, Aug. 2022.
9. S. Sarkar, I. V. Singh, and B. K. Mishra, “A simple and efficient implementation of localizing gradient damage method in COMSOL for fracture simulation,” Eng Fract Mech, vol. 269, p. 108552, Jun. 2022.
10. D. Modupeola and P. Patricia, “Optimizing the maximum strain of a laser-deposited high-entropy alloy using COMSOL multiphysics,” Beni Suef Univ J Basic Appl Sci, vol. 13, no. 1, pp. 1–8, Dec. 2024.
11. P. Peyre, M. Dal, S. Pouzet, and O. Castelnau, “Simplified numerical model for the laser metal deposition additive manufacturing process,” J Laser Appl, vol. 29, no. 2, May 2017.
12. F. Caiazzo and V. Alfieri, “Simulation of Laser-assisted Directed Energy Deposition of Aluminum Powder: Prediction of Geometry and Temperature Evolution,” Materials 2019, Vol. 12, Page 2100, vol. 12, no. 13, p. 2100, Jun. 2019.
13. F. Wirth and K. Wegener, “A physical modeling and predictive simulation of the laser cladding process,” Addit Manuf, vol. 22, pp. 307–319, Aug. 2018.
14. W. Ya, B. Pathiraj, and S. Liu, “2D modelling of clad geometry and resulting thermal cycles during laser cladding,” J Mater Process Technol, vol. 230, pp. 217–232, Apr. 2016.
15. B. K. Panda, S. Sarkar, and A. K. Nath, “2D thermal model of laser cladding process of Inconel 718,” Mater Today Proc, vol. 41, pp. 286–291, 2019.
16. S. Saroj, C. K. Sahoo, and M. Masanta, “Microstructure and mechanical performance of TiC-Inconel825 composite coating deposited on AISI 304 steel by TIG cladding process,” J Mater Process Technol, vol. 249, pp. 490–501, Nov. 2017, Accessed: Nov. 07, 2024. [Online]. Available: https://www.researchgate.net/publication/317944313_Microstructure_and_mechanical_performance_of_TiC-Inconel825_composite_coating_deposited_on_AISI_304_steel_by_TIG_cladding_process
17. Daniel Ghiculescu, Liviu Nita, Jozsef Pop, and Andrei Rusu, “COMPARATIVE STUDY BETWEEN PLASMA AND LASER CUTTING OF STEELS AND POLYMERIC MATERIALS,” in Revista de Tehnologii Neconventionale, vol. 26, Nonconventional Technologies Review, 2022, ch. 4, pp. 49–54.
18. J. Ning et al., “Microstructure and mechanical properties of SiC-reinforced Inconel 718 composites fabricated by laser cladding,” Surf Coat Technol, vol. 463, p. 129514, Jun. 2023.
Published
2025-03-31
How to Cite
Rusu, A., Bunea, A., & Ghiculescu, L. (2025). STUDY OF THERMAL DISTRIBUTION AND CLADDING GEOMETRY DURING LASER METAL DEPOSITION PROCESS USING FINITE ELEMENT ANALYSIS. Nonconventional Technologies Review, 29(1). Retrieved from https://www.revtn.ro/index.php/revtn/article/view/510
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Articles
