<p>Laser Directed Energy Deposition (L-DED) is an additive manufacturing technique that fabricates metallic parts by melting and depositing material layer by layer. In wire-based L-DED, controlling the wire temperature is essential to ensure deposition stability, minimize defects, and improve component quality. A promising approach is inductive preheating, where an electromagnetic coil increases the wire temperature before it enters the melt pool, reducing thermal gradients and enhancing process robustness. This work presents the analytical modeling and simulation of a low-frequency electromagnetic heating system for wire preheating in L-DED. Mathematical models were developed to estimate the magnetic field, induced current, heat generation, and temperature rise in the wire. These models provide insight into the system’s physical behavior and guide the design of the coil. The coil, conceived for laboratory experiments, was evaluated using both analytical methods and finite element simulations. The electromagnetic analysis considered the interaction between the coil’s alternating magnetic field and the induced currents in the wire, which generate heat through resistive losses. Subsequently, a thermal analysis estimated the resulting temperature rise. Although simplifications were adopted, such as neglecting temperature-dependent magnetic properties, the models yielded useful approximations of the heating system’s behavior. The developed system will be applied in future studies to improve the L-DED process by enabling consistent wire preheating, thereby enhancing deposition stability, reducing variability, and improving overall part quality. Additionally, the modeling approach can be adapted to different wire materials, feed rates, and ambient conditions, demonstrating the versatility of the proposed system for diverse applications.</p>

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Evaluation of magnetic field behavior and heating efficiency of an inductive preheating coil for wire-based laser directed energy deposition (L-DED)

  • Manoel Kolling Dutra,
  • Caio Linhares Prujansky,
  • Milton Pereira,
  • Régis Henrique Gonçalves e Silva,
  • Adroaldo Raizer,
  • Emanoel Pereira Elias

摘要

Laser Directed Energy Deposition (L-DED) is an additive manufacturing technique that fabricates metallic parts by melting and depositing material layer by layer. In wire-based L-DED, controlling the wire temperature is essential to ensure deposition stability, minimize defects, and improve component quality. A promising approach is inductive preheating, where an electromagnetic coil increases the wire temperature before it enters the melt pool, reducing thermal gradients and enhancing process robustness. This work presents the analytical modeling and simulation of a low-frequency electromagnetic heating system for wire preheating in L-DED. Mathematical models were developed to estimate the magnetic field, induced current, heat generation, and temperature rise in the wire. These models provide insight into the system’s physical behavior and guide the design of the coil. The coil, conceived for laboratory experiments, was evaluated using both analytical methods and finite element simulations. The electromagnetic analysis considered the interaction between the coil’s alternating magnetic field and the induced currents in the wire, which generate heat through resistive losses. Subsequently, a thermal analysis estimated the resulting temperature rise. Although simplifications were adopted, such as neglecting temperature-dependent magnetic properties, the models yielded useful approximations of the heating system’s behavior. The developed system will be applied in future studies to improve the L-DED process by enabling consistent wire preheating, thereby enhancing deposition stability, reducing variability, and improving overall part quality. Additionally, the modeling approach can be adapted to different wire materials, feed rates, and ambient conditions, demonstrating the versatility of the proposed system for diverse applications.