Transport phenomena during direct metal deposition

The evolution of temperature and velocity fields during direct metal deposition with coaxial powder injection was simulated using a self-consistent three-dimensional model based on the solution of the equations of mass, momentum, energy conservation, and solute transport in the liquid pool. The basic physical phenomena, including heat transfer, phase changes, mass addition, fluid flow, and interactions between the laser beam and the coaxial powder flow, were considered in the model. The level-set method was implemented to track the evolution of the liquid/gas interface. The temperature and velocity fields, liquid/gas interface, and energy distribution at liquid/gas interface at different times were simulated. For verification purposes, the cladding depth and height were compared with experimental results. (c) 2007 American Institute of Physics.