This study undertakes a comprehensive comparison of two prominent metal additive manufacturing processes from the Directed Energy Deposition (DED) family, Laser Engineered Net Shaping (LENS) and Laser Wire Additive Manufacturing (LWAM), specifically focusing on their application in printing the Ti-6Al-4V titanium alloy. Beyond evaluating these processes in practical terms, our research delves into the comparative analysis of advanced simulation models developed to accurately predict the thermo-microstructural evolution within Ti-6Al-4V parts fabricated by these methods. Through integrating transient finite element thermal models with density-based microstructural models to predict the α-phase fractions, β-phase fraction, and alpha lath widths, we aim to elucidate the nuanced differences in microstructure and phase transformations in the titanium alloy printed by each process. The study identifies four stages of phase transformations, including the transformation from β phase to α phase, and the elimination of α’ phase during the LWAM process. In addition, this study compares these two processes, from the point of view of their efficiency and their potential for industrial applications. Results show that LWAM exhibits higher deposition rates and flexibility, while LENS offers precise control over microstructural characteristics. Our findings provide valuable insights for optimizing process parameters to achieve desired mechanical properties, enhancing the potential for industrial applications.

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Comparative Analysis of Simulation Models for LENS and LWAM Processes in Ti-6Al-4V Additive Manufacturing

  • Larbi Yousfi,
  • Amir Guizani,
  • Moncef Hammadi,
  • Slim Bouaziz,
  • Mohamed Haddar

摘要

This study undertakes a comprehensive comparison of two prominent metal additive manufacturing processes from the Directed Energy Deposition (DED) family, Laser Engineered Net Shaping (LENS) and Laser Wire Additive Manufacturing (LWAM), specifically focusing on their application in printing the Ti-6Al-4V titanium alloy. Beyond evaluating these processes in practical terms, our research delves into the comparative analysis of advanced simulation models developed to accurately predict the thermo-microstructural evolution within Ti-6Al-4V parts fabricated by these methods. Through integrating transient finite element thermal models with density-based microstructural models to predict the α-phase fractions, β-phase fraction, and alpha lath widths, we aim to elucidate the nuanced differences in microstructure and phase transformations in the titanium alloy printed by each process. The study identifies four stages of phase transformations, including the transformation from β phase to α phase, and the elimination of α’ phase during the LWAM process. In addition, this study compares these two processes, from the point of view of their efficiency and their potential for industrial applications. Results show that LWAM exhibits higher deposition rates and flexibility, while LENS offers precise control over microstructural characteristics. Our findings provide valuable insights for optimizing process parameters to achieve desired mechanical properties, enhancing the potential for industrial applications.