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<p>Laser metal deposition (LMD) is a laser-based additive manufacturing process that builds metallic components from CAD models, crucial for rapid prototyping, tooling, and part refurbishment. Developing accurate predictive models for LMD is complex due to the numerous variables involved. This study introduces a comprehensive heat transfer and fluid dynamics model, employing a continuum approach for all phases and a force–balance flow algorithm with moving mesh theory to simulate surface tension. The model incorporates laser–powder interactions and temperature-dependent properties to improve accuracy. Experimental validation with a 300&#xa0;mm × 300&#xa0;mm × 10&#xa0;mm sample using an IPG YLS-16000 laser showed a 3.7% error in track height and 6.2% in width. Incorporating a secondary laser heat source (SLHS) significantly influenced track dimensions, cooling rates, and solidification. Without SLHS, track width increased from 17.8&#xa0;mm to 33&#xa0;mm as laser power rose from 600&#xa0;W to 925&#xa0;W. With SLHS, it ranged from 15.1&#xa0;mm to 24.7&#xa0;mm. These results underscore the role of advanced numerical models in optimizing LMD processes, enhancing manufacturing quality and resource efficiency.</p>

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Predictive Modeling of Laser Metal Deposition with Moving Mesh Theory: Impact of Secondary Laser Heat Sources on Track Morphology

  • 期刊论文

  • 发表日期：

    2025年1月7日

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  • Zary Adabavazeh,
  • Yi-Jen Huang

摘要

Laser metal deposition (LMD) is a laser-based additive manufacturing process that builds metallic components from CAD models, crucial for rapid prototyping, tooling, and part refurbishment. Developing accurate predictive models for LMD is complex due to the numerous variables involved. This study introduces a comprehensive heat transfer and fluid dynamics model, employing a continuum approach for all phases and a force–balance flow algorithm with moving mesh theory to simulate surface tension. The model incorporates laser–powder interactions and temperature-dependent properties to improve accuracy. Experimental validation with a 300 mm × 300 mm × 10 mm sample using an IPG YLS-16000 laser showed a 3.7% error in track height and 6.2% in width. Incorporating a secondary laser heat source (SLHS) significantly influenced track dimensions, cooling rates, and solidification. Without SLHS, track width increased from 17.8 mm to 33 mm as laser power rose from 600 W to 925 W. With SLHS, it ranged from 15.1 mm to 24.7 mm. These results underscore the role of advanced numerical models in optimizing LMD processes, enhancing manufacturing quality and resource efficiency.