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<p>Directed energy deposition (DED) is an additive manufacturing process for fabricating large components and repairing parts. Unlike laser powder bed fusion, DED enables faster fabrication by delivering powder with a carrier gas and a high-energy heat source. However, transient melting and solidification pose challenges. To address this, a two-stage finite volume method (FVM) framework was developed: 1) a computational fluid dynamics (CFD) and Lagrangian discrete phase model (DPM) to estimate powder mass flow at the focal plane and 2) a thermo-fluid analysis to characterize the melt pool. The first stage considers turbulence and particle forces, aligning well with experiments. The second stage integrates solidification, evaporation, multiple heat reflections, and Marangoni effects for accurate melt pool prediction. Results show carrier and shield gases influence powder in-flight behavior, and powder injection affects melt pool morphology, providing insights into DED melt pool formation.</p>

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A fully computational approach for the prediction of melt pool generation of the directed energy deposition process

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Mingyu Chung,
  • Kang-Hyun Lee,
  • Jaeeun Park,
  • Yoon Sun Lee,
  • Gun Jin Yun

摘要

Directed energy deposition (DED) is an additive manufacturing process for fabricating large components and repairing parts. Unlike laser powder bed fusion, DED enables faster fabrication by delivering powder with a carrier gas and a high-energy heat source. However, transient melting and solidification pose challenges. To address this, a two-stage finite volume method (FVM) framework was developed: 1) a computational fluid dynamics (CFD) and Lagrangian discrete phase model (DPM) to estimate powder mass flow at the focal plane and 2) a thermo-fluid analysis to characterize the melt pool. The first stage considers turbulence and particle forces, aligning well with experiments. The second stage integrates solidification, evaporation, multiple heat reflections, and Marangoni effects for accurate melt pool prediction. Results show carrier and shield gases influence powder in-flight behavior, and powder injection affects melt pool morphology, providing insights into DED melt pool formation.