Abstract Direct energy deposition (DED) is an effective method to fabricate complex metal thin-wall structures. The geometrical dimensions of the cladding track have significant influence on the dimensional precision of final components. In this study, a powder-scale multi-physics model using the Finite Volume Method (FVM) is developed to study the direct energy deposition process. The mass transfer, phase transformations and heat transfer in the DED process are incorporated and the geometrical characteristics of a single cladding track can be rapidly predicted. The influences of the process parameters including laser power, powder feed rate and scanning speed on the track width and height are analyzed in detail using an analysis of variance (ANOVA) method. Based on the simulation results, a Gaussian process regression (GPR) model is developed to predict the geometrical characteristics of cladding tracks under different manufacturing parameters. Finally, both the multi-physics model and the GPR model are validated by single track deposition experiments. The results show that the proposed multi-physics simulation results are in good agreement with the experimental results and can reveal the qualitative relationship between parameters and track geometry. The GPR model is able to predict the geometrical characteristics of single cladding tracks.

中文翻译：

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用于直接能量沉积的熔覆轨道几何形状的多物理场建模和高斯过程回归分析

摘要 直接能量沉积（DED）是制备复杂金属薄壁结构的有效方法。包层轨道的几何尺寸对最终部件的尺寸精度有显着影响。在本研究中，开发了使用有限体积法 (FVM) 的粉末尺度多物理场模型来研究直接能量沉积过程。将 DED 过程中的传质、相变和热传递结合在一起，可以快速预测单个包层轨道的几何特征。使用方差分析（ANOVA）方法详细分析了激光功率、送粉速度和扫描速度等工艺参数对轨道宽度和高度的影响。根据仿真结果，开发了高斯过程回归 (GPR) 模型来预测不同制造参数下熔覆轨道的几何特征。最后，多物理场模型和探地雷达模型均通过单道沉积实验验证。结果表明，所提出的多物理场仿真结果与实验结果吻合良好，可以揭示参数与轨道几何形状之间的定性关系。GPR 模型能够预测单个包层轨迹的几何特征。结果表明，所提出的多物理场仿真结果与实验结果吻合良好，可以揭示参数与轨道几何形状之间的定性关系。GPR 模型能够预测单个包层轨迹的几何特征。结果表明，所提出的多物理场仿真结果与实验结果吻合良好，可以揭示参数与轨道几何形状之间的定性关系。GPR 模型能够预测单个包层轨迹的几何特征。