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<p>Standard laser-directed energy deposition (DED-L) processes based on horizontal substrates and vertically incident laser beams are often inadequate for accommodating complex and variable engineering scenarios. In this study, a computational fluid dynamic (CFD) model based on the volume-of-fluid (VOF) approach was developed to simulate DED-L on inclined substrates, incorporating recoil pressure and Mie scattering effects. A combined experimental and numerical methodology was employed to analyze the formation of melt pool geometry and the associated thermal-mass transport behaviors under varying energy input and gravitational influences across distinct deposition strategies. The results indicate that higher laser power significantly improves powder utilization, leading to increased melt volume and enlarged cross-sectional dimensions. Within a substrate inclination range of 0–45°, greater inclination angles induce downward molten metal flow, thereby reducing melt pool height, depth, and cross-sectional area while increasing width and positional offset. Moreover, increased substrate tilt markedly elevates residual stress within the deposited layer. Comparative assessments of various cladding strategies demonstrate that optimizing deposition orientation effectively reduces residual stress accumulation. These findings offer critical insights into the influence of substrate inclination on DED-L and lay a foundation for process parameter optimization aimed at enhancing cladding quality and structural performance.</p>

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Investigation of Heat-Mass Transfer and Residual Stress of Laser-Directed Energy Deposition Under Multiple Cladding Categories

  • 期刊论文

  • 发表日期：

    2026年4月2日

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  • Yanming Liu,
  • Weiwei Liu,
  • Jinhua Ouyang,
  • Yali Ma,
  • Fengtao Wang,
  • Hongchao Zhang

摘要

Standard laser-directed energy deposition (DED-L) processes based on horizontal substrates and vertically incident laser beams are often inadequate for accommodating complex and variable engineering scenarios. In this study, a computational fluid dynamic (CFD) model based on the volume-of-fluid (VOF) approach was developed to simulate DED-L on inclined substrates, incorporating recoil pressure and Mie scattering effects. A combined experimental and numerical methodology was employed to analyze the formation of melt pool geometry and the associated thermal-mass transport behaviors under varying energy input and gravitational influences across distinct deposition strategies. The results indicate that higher laser power significantly improves powder utilization, leading to increased melt volume and enlarged cross-sectional dimensions. Within a substrate inclination range of 0–45°, greater inclination angles induce downward molten metal flow, thereby reducing melt pool height, depth, and cross-sectional area while increasing width and positional offset. Moreover, increased substrate tilt markedly elevates residual stress within the deposited layer. Comparative assessments of various cladding strategies demonstrate that optimizing deposition orientation effectively reduces residual stress accumulation. These findings offer critical insights into the influence of substrate inclination on DED-L and lay a foundation for process parameter optimization aimed at enhancing cladding quality and structural performance.