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Laser beam absorptance effects during wire directed energy deposition
University West, Department of Engineering Science, Division of industrial automation. (KAMPT)ORCID iD: 0009-0003-6518-0719
University West, Department of Engineering Science, Division of industrial automation. (KAMPT)ORCID iD: 0000-0002-8771-7404
University West, Department of Engineering Science, Division of mechanical engineering. (KAMPT)ORCID iD: 0000-0003-0194-9018
2026 (English)In: Applied Physics A: Materials Science & Processing, ISSN 0947-8396, E-ISSN 1432-0630, Vol. 132, no 9, article id 914Article in journal (Refereed) Published
Abstract [en]

Laser energy absorption plays an important role in determining process stability and energy efficiency in wire Directed Energy Deposition using a laser beam. However, the combined influence of wire geometry, beam positioning, and temperature-dependent optical properties on absorbed laser power remains insufficiently understood. This work presents an analytical framework for predicting the absorptance and absorbed power during the processing of Inconel 718. The model combines Monte Carlo ray tracing, Fresnel reflection theory, and a temperature-dependent Drude formulation in which the optical properties are related to electrical resistivity. A parametric investigation was conducted to evaluate the effects of wire-feeding angle, beam-wire offset, melt pool temperature, and wire temperature. The results showed that increasing the wire feeding angle altered the incidence-angle distribution of laser rays on the wire surface, resulting in non-monotonic variations in wire absorptance and absorbed power despite increasing beam interception. Furthermore, the interaction between wire and melt pool temperatures revealed three operating regimes governing the response of absorbed power to beam-wire offset. When the wire absorptance was lower than that of the melt pool, absorbed power increased with increasing offset, whereas the opposite trend occurred when the wire absorptance exceeded that of the melt pool. Between these regimes, a compensation condition was identified in which absorbed power remained nearly independent of beam-wire offset. This behavior occurred when the wire absorptance approached that of the melt pool, minimizing the influence of laser-energy redistribution between both surfaces. For the investigated geometry and optical assumptions, the compensation condition was associated with an approximately constant electrical-resistivity ratio and a constant relationship between the compensation wire temperature and melt pool temperature.

Place, publisher, year, edition, pages
2026. Vol. 132, no 9, article id 914
Keywords [en]
Laser absorptance, Wire directed energy deposition, Laser-material interaction, Fresnel equations, Drude model, Inconel 718, Absorbed power
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-26112DOI: 10.1007/s00339-026-10099-yISI: 001857466300018Scopus ID: 2-s2.0-105048086655OAI: oai:DiVA.org:hv-26112DiVA, id: diva2:2097462
Funder
Knowledge Foundation
Note

CC BY 4.0

Acknowledgements

The authors acknowledge funding from the Knowledge Foundation (KK stiftelsen), Sweden for the project DEDICATE—Directed Energy Deposition for Industrial Competitiveness in Additive Manufacturing Technologies and from Horizon Europe for the project REPAM—Resource efficient materials for Additive Manufacturing (grant: 101178659).

Available from: 2026-09-01 Created: 2026-09-01 Last updated: 2026-09-01

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Sahraeidolatkhaneh, AtiehNilsen, MorganVolpp, Jörg

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1213141516171815 of 217
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