The surface roughness of additive manufactured parts is usually high and not satisfactory for any aimed application. Surface structuring by laser remelting (WaveShape) is a novel laser-based process in which surface structures are mainly created or deleted by reallocation of molten material. Since fundamental aspects of the formation of surface structure in laser remelting are neither fully understood nor completely covered by current models, an enhanced FEM model was developed. Numerical results based on this FEM model suggest that fundamental factors in the formation of surface structures are deformations of the melt pool surface due to changes in the volume of molten material and due to temporal, localized vapor pressure. Based on single track experiments on prepared Inconel 718 specimen, the numerical calculations have been evaluated for a Nd:YAG laser beam source, with a beam diameter of 250 μm, using scan speeds from 25 mm/s to 200 mm/s and a sinusoidal modulation of laser power between 20 W and 225 W. The good agreement of numerical calculations and experimental results indicate that essential effects in surface structure formation were successfully identified. Marangoni convection seems to have virtually no or just a small impact on the formation of surface structures in laser remelting.

增材制造零件的表面粗糙度通常很高，对于任何目标应用而言都不令人满意。通过激光重熔（WaveShape）进行的表面结构化是一种基于激光的新颖过程，其中主要通过重新分配熔融材料来创建或删除表面结构。由于目前的模型既未完全理解也未完全涵盖激光重熔中表面结构形成的基本方面，因此开发了增强型FEM模型。基于该有限元模型的数值结果表明，表面结构形成的基本因素是熔池表面的变形，这是由于熔融材料体积的变化以及时间，局部蒸汽压引起的。基于对准备好的Inconel 718试样的单轨实验，对Nd的数值计算进行了评估：YAG激光束源，光束直径为250μm，扫描速度为25 mm / s至200 mm / s，并且激光功率的正弦调制在20 W至225 W之间。数值计算和实验结果吻合良好，表明成功识别了表面结构形成的基本作用。Marangoni对流似乎对激光重熔中表面结构的形成几乎没有影响或影响很小。