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Multi-physics modeling of direct energy deposition process of thin-walled structures: defect analysis

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Abstract

As a promising additive manufacturing method, direct energy deposition has been widely used to fabricate complex thin-walled parts. However, some defects such as uneven layer surface and excessive build-ups always occur in this process. In this study, a high-fidelity model adopting a novel laser/powder source is developed to simulate the detailed multi-layer deposition process. With layer surfaces being tracked in real-time, laser source model incorporates local incidence angle and defocusing amount to adjust absorbed energy and beam radius on the track surfaces. The powder catchment efficiency varies with the defocusing amount timely. The simulations demonstrate that build-ups are mainly induced by unstable linear powder feed rate and worsen due to laser/powder defocusing and accumulated heat. The layer surface unevenness results from powder positive defocusing, while molten pool dynamics, laser positive defocusing and accumulated heat plays a supplementary role. Eliminating methods are proposed based on the simulations and validated by experiments.

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Acknowledgements

This research is supported by the National Research Foundation, Prime Minister’s Office, Singapore under its Campus for Research Excellence and Technological Enterprise (CREATE) program. Shuhao Wang acknowledges the support by China Scholarship Council. Lida Zhu acknowledges the support by the National Natural Science Foundation of China (51975112).

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Author notes

  1. Shuhao Wang and Lida Zhu have contributed equally to this work.

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China

    Shuhao Wang, Lida Zhu, Yichao Dun & Zhichao Yang

  2. Department of Mechanical Engineering, National University of Singapore, Singapore, 117575, Singapore

    Shuhao Wang, Jerry Ying Hsi Fuh & Wentao Yan

  3. Campus for Research Excellence and Technological Enterprise (CREATE), Singapore, 138602, Singapore

    Wentao Yan

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  1. Shuhao Wang
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  2. Lida Zhu
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  3. Yichao Dun
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  4. Zhichao Yang
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  5. Jerry Ying Hsi Fuh
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  6. Wentao Yan
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Correspondence to Wentao Yan.

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Wang, S., Zhu, L., Dun, Y. et al. Multi-physics modeling of direct energy deposition process of thin-walled structures: defect analysis. Comput Mech 67, 1229–1242 (2021). https://doi.org/10.1007/s00466-021-01992-9

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  • DOI: https://doi.org/10.1007/s00466-021-01992-9

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