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<p>Laser Directed Energy Deposition (LDED) is widely used in aerospace and automotive industries for rapid manufacturing and repair. In this process, interactions between the powder flow and the molten pool strongly affect part quality. This study presents a coupled numerical model of powder flow dynamics and molten pool evolution in LDED to analyze spatial powder convergence and thermal field behavior. ANSYS Fluent simulations were conducted by coupling fluid heat transfer, laminar flow, and an improved Gaussian heat source model. The effects of carrier gas flow rate, coefficient of restitution, laser power, scanning speed, powder feed rate, and laser spot radius on powder distribution and molten pool thermal dynamics were evaluated. The results show that optimal powder convergence occurs at a coefficient of restitution of 0.91. Carrier gas flow rate and powder feed rate have the most significant effects on spatial powder distribution. The coupled model demonstrates that powder absorption increases the peak temperature of the molten pool compared with the uncoupled model that neglects powder flow-molten pool interactions. In addition, laser power, scanning speed, and carrier gas flow rate play critical roles in controlling thermal gradients. Experimental validation confirms that the model accurately predicts molten pool morphology, demonstrating its utility for process optimization. Overall, this study provides fundamental insights into the governing physics of LDED and supports improved process control and enhanced manufacturing quality.</p>

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Multi-physics modeling of process parameter effects on powder flow convergence and thermal distribution in laser directed energy deposition

  • 期刊论文

  • 发表日期：

    2026年6月23日

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  • Kaixiong Hu,
  • Yiwei Wang,
  • Yong Zhou,
  • Weidong Li

摘要

Laser Directed Energy Deposition (LDED) is widely used in aerospace and automotive industries for rapid manufacturing and repair. In this process, interactions between the powder flow and the molten pool strongly affect part quality. This study presents a coupled numerical model of powder flow dynamics and molten pool evolution in LDED to analyze spatial powder convergence and thermal field behavior. ANSYS Fluent simulations were conducted by coupling fluid heat transfer, laminar flow, and an improved Gaussian heat source model. The effects of carrier gas flow rate, coefficient of restitution, laser power, scanning speed, powder feed rate, and laser spot radius on powder distribution and molten pool thermal dynamics were evaluated. The results show that optimal powder convergence occurs at a coefficient of restitution of 0.91. Carrier gas flow rate and powder feed rate have the most significant effects on spatial powder distribution. The coupled model demonstrates that powder absorption increases the peak temperature of the molten pool compared with the uncoupled model that neglects powder flow-molten pool interactions. In addition, laser power, scanning speed, and carrier gas flow rate play critical roles in controlling thermal gradients. Experimental validation confirms that the model accurately predicts molten pool morphology, demonstrating its utility for process optimization. Overall, this study provides fundamental insights into the governing physics of LDED and supports improved process control and enhanced manufacturing quality.