Modeling of Temperature Field Evolution During Multilayered Direct Laser Metal Deposition

It is of great importance to thoroughly explore the evolving temperature fields of direct laser metal deposition (abbreviated as LMD) in vertical thin wall manufacturing. It is helpful to control the temperature gradient, and even to adjust to forming microstructures and accumulation of residual stress. In this paper, a comprehensive three-dimensional transient model is developed for evolving temperature fields. The manufactured material is DS superalloy Rene80. The laser-powder interaction during the powder flowing process is simulated first, and its possible effect on the temperature field of the melting pool is analyzed. Then a 3D numerical simulation for the evolving temperature field is carried out based on considering transport phenomena during LMD such as the change in phase, powder injection and liquid flow. The applied deposition parameters are derived from experimental investigation with optimized vertical wall manufacturing. The simulated results explain why a balance between heat input and dissipation could form inside the vertical thin wall. These reconstruct the instability at an early phase of the building process without any temperature control unit and exhibit the influence of parameters such as laser power, deposition velocity and laser beam deposition pattern. The simulation results of temperature evolution are consistent with experimental investigation.