Impact of Intermittent Laser on Thermal History in Directed Energy Deposition: A Numerical Study
摘要
DED (directed energy depositionDirected energy deposition) techniques have recently been implemented across various industries. The advantages of DED technology enable the production of complex geometries, making it particularly useful for manufacturing performance critical components, such as medical components, aerospace, and automotive parts. Numerous studies have investigated heat transfer and cooling history in DED. These parametric factors such as temperature, velocity, pressure and melting poolMelt pool size are closely linked to the results of microstructureMicrostructure and mechanical propertiesMechanical properties. Recent studies have shown that using intermittent laserIntermittent laser modes potentially improves the velocity and pressure in melt poolsMelt pool and rapid changes in cooling rates. That helps the stabilization in melt pools leads to enhanced microstructure and mechanical properties, but the underlying mechanism involving thermal history is not fully understood. It is challenging to track the complete thermal history through experimental studies. Therefore, a numerical model is proposed to predict melt pool size and temperature distribution that is affecting the solidification and cooling process, for both continuous and intermittent laser modes in DED of 316L stainless steelStainless steel. SimulationSimulation models are studied for different laser modes, showing a significant effect on surface temperature distribution. This contributes to molten pool formation and influences velocity and pressure, thereby affecting the contour patterns. The effects of shock mechanism in intermittent laser on melt pool are discussed, which significantly effects the melt pool periphery, center velocity of melt pool and edge pressure of melts poolMelt pool. Overall, intermittent lasersIntermittent laser produce a smaller melt poolMelt pool compared to continuous lasersContinuous laser, as the shorter heat transfer duration results in a faster cooling rate, reducing the thermally affected area and leading to finer microstructuresMicrostructure. In contrast, continuous lasersContinuous laser mode sustains heat transfer over a longer duration, allows maximum heat transfer, that leads to a bigger melt poolMelt pool and promotes grain growth as a result gives coarser microstructures. Intermittent lasersIntermittent laser create a shocking and shaking mechanism in melt poolsMelt pool, that allows stabilize melt poolMelt pool on lower temperatureTemperature as well as short duration gives fast cooling.