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Influence of laser-wire interaction on heat and metal transfer in directed energy deposition
University West, Department of Engineering Science, Division of Welding Technology. (KAMPT)ORCID iD: 0000-0002-6102-9021
University West, Department of Engineering Science, Division of Production Systems. (KAMPT)ORCID iD: 0000-0002-8018-6145
University West, Department of Engineering Science, Division of Production Systems. (KAMPT)ORCID iD: 0000-0002-2527-1048
University West, Department of Engineering Science, Division of Production Systems. (KAMPT)ORCID iD: 0000-0001-5734-294X
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2023 (English)In: International Journal of Heat and Mass Transfer, ISSN 0017-9310, E-ISSN 1879-2189, Vol. 205, article id 123894Article in journal (Refereed) Published
Abstract [en]

In this study, laser metal fusion with feedstock wire is addressed. We investigated how various process parameters affect the fraction of beam energy that is absorbed by the wire and the workpiece and the metal transfer from the feedstock wire to the melt pool. To perform this research, a thermo-fluid dynamic model with tracking of free surface deformation was developed to include the feeding of a solid wire and predict its melting. The fraction of beam energy absorbed by the metal was modeled as a function of local surface curvature and temperature, accounting for multiple Fresnel reflections and absorptions. The model was applied to Titanium alloy (Ti-6Al-4V) with a 1.07 μm laser and a process in conduction mode. Experiments at various wire feeding rates were conducted to evaluate the model’s ability to predict the process and a good agreement was obtained. The different parameters studied were the beam angular position, the wire angular position, the wire feed rate, and the beam-wire offset. The analysis of the simulation results gave a detailed physical understanding of the laser energy use. It highlighted that thermocapillary and Rayleigh-Plateau instabilities can contribute to the transition from continuous to drop metal transfer mode. Damping these instabilities might thus allow using a wider process window.

Place, publisher, year, edition, pages
2023. Vol. 205, article id 123894
Keywords [en]
Laser beam, Feedstock wire, Metal fusion, Metal deposition, Energy deposition, Process stability, CFD Simulation
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-20037DOI: 10.1016/j.ijheatmasstransfer.2023.123894ISI: 000965022600001Scopus ID: 2-s2.0-85147203744OAI: oai:DiVA.org:hv-20037DiVA, id: diva2:1766614
Funder
Knowledge Foundation, 20170315
Note

 CC BY-NC-ND 

This research work was supported by grants from the Swedish Knowledge Foundation, projects AdOpt (20170315) and SAMw(20170060), which is gratefully acknowledged.

Available from: 2023-06-13 Created: 2023-06-13 Last updated: 2024-01-08Bibliographically approved

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Noori Rahim Abadi, Seyyed Mohammad AliMi, YongcuiKisielewicz, AgnieszkaSikström, FredrikChoquet, Isabelle

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Manufacturing, Surface and Joining Technology

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