An analytical-numerical model of laser direct metal deposition track and microstructure formation

Multiple analytical and numerical models of the laser metal deposition process have been presented, but most rely on sequential solution of the energy and mass balance equations or discretization of the problem domain. Laser direct metal deposition is a complex process involving multiple interdependent processes which can be best simulated using a fully coupled mass-energy balance solution. In this work a coupled analytical-numerical solution is presented. Sub-models of the powder stream, quasi-stationary conduction in the substrate and powder assimilation into the area of the substrate above the liquidus temperature are combined. An iterative feedback loop is used to ensure mass and energy balances are maintained at the melt pool. The model is verified using Ti-6Al-4V single track deposition, produced with a coaxial nozzle and a diode laser. The model predictions of local temperature history, the track profile and microstructure scale show good agreement with the experimental results. The model is a useful industrial aid and alternative to finite element methods for selecting the parameters to use for laser direct metal deposition when separate geometric and microstructural outcomes are required.