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<p>This study investigates how powder affects the thermal and hydrodynamic behavior in laser-directed metal deposition (DMD) molten pools. A multiphase numerical model, assuming incompressibility, laminar flow, and Gaussian heat distribution, was used to simulate the DMD process, focusing on energy balance, enthalpy–porosity, mass, and momentum conservation. Validation with 316L stainless steel powder showed high accuracy, with parameter deviations between 4.56% and 8.82%. Powder velocity significantly affected melt pool characteristics, with initial increases in maximum temperature and length followed by decreases, and a consistent rise in fluid velocity. These effects influence the quality of the deposited layer. Larger powder particles required more energy to melt, leading to uneven energy distribution and lower maximum temperatures but a larger melt pool size. The research provides a theoretical basis for optimizing DMD parameters, exploring materials, and improving deposition quality, highlighting the importance of numerical simulation in DMD research and optimization.</p>

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Numerical Simulation-Based Analysis of the Role of Powders in Influencing Thermal and Hydrodynamic Behavior of the Melt Pool During Laser-Directed Metal Deposition

  • 期刊论文

  • 发表日期：

    2026年3月31日

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  • Xu Pei,
  • Liang Wang,
  • Kai Zhao

摘要

This study investigates how powder affects the thermal and hydrodynamic behavior in laser-directed metal deposition (DMD) molten pools. A multiphase numerical model, assuming incompressibility, laminar flow, and Gaussian heat distribution, was used to simulate the DMD process, focusing on energy balance, enthalpy–porosity, mass, and momentum conservation. Validation with 316L stainless steel powder showed high accuracy, with parameter deviations between 4.56% and 8.82%. Powder velocity significantly affected melt pool characteristics, with initial increases in maximum temperature and length followed by decreases, and a consistent rise in fluid velocity. These effects influence the quality of the deposited layer. Larger powder particles required more energy to melt, leading to uneven energy distribution and lower maximum temperatures but a larger melt pool size. The research provides a theoretical basis for optimizing DMD parameters, exploring materials, and improving deposition quality, highlighting the importance of numerical simulation in DMD research and optimization.