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Phenomenological modelling of direct laser metal deposition for single tracks

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Abstract

The direct laser metal deposition (DLMD) is an emerging technology in the additive manufacturing field, which is becoming widely adopted in several industrial applications. The optimal selection of process parameters is critical, given the cost of physical tests and the requirement for high-quality manufacturing. Correct forecasting of process parameters using predictive physical models is a viable alternative to shorten the setup phase and improve the sustainability. In this paper, firstly, several models available so far in the literature are reviewed, and then, a general model is derived to evaluate the best combination of process parameters in single track operations. The proposed phenomenological model allows simple forecasting based on three main process parameters: laser power (P), powder feed rate (F) and translation speed (V). An innovative approach is proposed to generalise the model and overcome the “try and error” method used in numerous works to determine the exponents (α, β, γ). The model was designed considering the physical parameters which best explained the variability of the exponents: the thermal diffusivity of the base material and the density of the powder material. The best ranges of the process parameter exponents are suggested to establish the most suitable combined parameters for the prediction of geometric characteristics of the clad. The potentialities of the model are proven based on an experimental case performed over a commercially available Nickel-based super-alloy powder. New formulations are recommended, which are in good agreement with the behaviours defined in the literature, as shown in the test case.

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Abbreviations

P:

Laser power

V:

Translation speed

F:

Powder feed rate

W:

Clad width

H:

Clad height

p:

Clad penetration depth

A c :

Clad area

A m :

Substrate molten area

Dil:

Dilution

Dt:

Thermal diffusivity

α:

Absorbance of powder

η d :

Laser power dependent deposition efficiency

η i :

Laser power independent deposition efficiency

η melt :

Substrate melting efficiency

ρ (p) :

Powder density

ρ (s) :

Substrate density

C (p) :

Specific heat of powder

T (p) :

Melting temperature of powder

L f(p) :

Latent heat of fusion of powder

C (s) :

Specific heat of substrate

T (s) :

Melting temperature of substrate

L f(s) :

Latent heat of fusion of substrate

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This research received no specific grant from any funding agency in the public, commercial, or not-for-profit sectors.

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Authors and Affiliations

  1. Department of Mechanics, Mathematics and Management, Politecnico di Bari, Via Orabona 4, 70125, Bari, Italy

    Marco Mazzarisi, Sabina Luisa Campanelli, Andrea Angelastro & Michele Dassisti

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  1. Marco Mazzarisi
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Correspondence to Marco Mazzarisi.

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Mazzarisi, M., Campanelli, S.L., Angelastro, A. et al. Phenomenological modelling of direct laser metal deposition for single tracks. Int J Adv Manuf Technol 111, 1955–1970 (2020). https://doi.org/10.1007/s00170-020-06204-x

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