Analytical solutions for rapid prediction of transient temperature field in powder-fed laser directed energy deposition based on different heat source models

Ansari, Mohammad; Khamooshi, Mehrdad; Huang, Yuze; Toyserkani, Ehsan

doi:10.1007/s00339-021-04591-w

Cited by 6 publications

(2 citation statements)

References 29 publications

(38 reference statements)

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“…The hightemperature molten pool influences the surrounding air, inducing natural convection and facilitating convective heat transfer between the molten pool and the external environment. Simultaneously, the molten pool exchanges thermal energy with the surroundings through thermal radiation [13], [14].…”

Section: B Cyclic Heat Transfer Modelmentioning

confidence: 99%

Residual Stress and Distortion Prediction for Laser Directed Energy Deposition Based on Cyclic Heat Transfer Model

Chai,

Li,

Miao

et al. 2024

IEEE Access

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Predicting the residual stress and distortion caused by inhomogeneous temperature fields in the laser directed energy deposition (LDED) process is a challenging task. This study proposes a novel thermodynamic coupling simulation method based on the cyclic heat transfer model to accurately predict temperature, stress, and distortion evolution during the deposition process. The model effectively calculates the layer-by-layer superposition of thermal effects and cyclic accumulation of thermal stress during the deposition process, leading to improved prediction accuracy for temperature, residual stress, and distortion. Initially, the heat source model, the cyclic heat transfer model, and the thermoelastic matrix are established. The thermoelastic constitutive equation and the equilibrium differential equation are formulated to capture the actual process characteristics of the LDED accurately in order to achieve the thermodynamic coupling solution. Then, numerical simulations are performed on a typical model specimen, with simulation parameters consistent with the actual deposition parameters. Finally, the predicted results are validated through actual deposition experiments, and the temperature, stress, and distortion history are analyzed. The results demonstrate that the cyclic thermodynamic coupling model proposed in this study can effectively predict the deposited components' temperature, residual stress, and distortion evolution. This study establishes a crucial foundation for achieving precision and performance control in the deposition process and reducing residual stress and distortion in the components.INDEX TERMS Laser directed energy deposition (LDED), cyclic heat transfer model, thermodynamic coupling, residual stress, distortion.

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Section: B Cyclic Heat Transfer Modelmentioning

confidence: 99%

Residual Stress and Distortion Prediction for Laser Directed Energy Deposition Based on Cyclic Heat Transfer Model

Chai,

Li,

Miao

et al. 2024

IEEE Access

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“…In relation to the melt pool and bulk-heating, analytical models are frequently utilized to forecast the dimensions of the melt pool as well as the thermal profile of the built part [296]. Ansari et al [301] conducted a more in-depth analysis by approximating the thermal and geometry profiles of a single-track using 1D, 2D, and 3D heat sources. These were further extended to multi-track, multi-layer deposition [302].…”

Section: Melt Pool Geometrical Modelling 651 Physics-based Approachmentioning

confidence: 99%

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

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This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems.

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Temperature evolution prediction for laser directed energy deposition enabled by finite element modelling and bi-directional gated recurrent unit

Hu,

Guo,

et al. 2024

Adv. Manuf.

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Analytical solutions for rapid prediction of transient temperature field in powder-fed laser directed energy deposition based on different heat source models

Cited by 6 publications

References 29 publications

Residual Stress and Distortion Prediction for Laser Directed Energy Deposition Based on Cyclic Heat Transfer Model

Residual Stress and Distortion Prediction for Laser Directed Energy Deposition Based on Cyclic Heat Transfer Model

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Temperature evolution prediction for laser directed energy deposition enabled by finite element modelling and bi-directional gated recurrent unit

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