Product Code: ICA10_404

An Iterative, Energy-Mass Balance Model for Laser Metal Deposition
Authors:
M Naveed Ahsan, School of Mechanical, Aerospace and Civil Engineering, The University of Manchester; Manchester Great Britain
Wei Wang, School of Mechanical, Aerospace and Civil Engineering, The University of Manchester; Manchester Great Britain
Andrew J Pinkerton, School of Mechanical, Aerospace and Civil Engineering, The University of Manchester; Manchester Great Britain
Presented at ICALEO 2010

Multiple analytical models of the laser metal deposition process have been presented, but most rely on
sequential solution of the energy and mass balance equations presented. Discretization of the problem domain
using finite element or similar code is typically used where a fully coupled mass-energy balance solution is
required, but the multi-phase nature of the process means it is difficult to establish an easily applied model of
track geometry via this method. In this work a coupled analytical solution is presented. Sub-models of the
powder stream, quasi-stationary conduction in the substrate, and powder assimilation into the area of the
substrate above the liquidus temperature, allowing for surface geometry factors, are combined. An iterative
feedback loop is used to ensure mass and energy balances are maintained at the melt pool. The model
predictions show good agreement with experimental melt pool temperatures and Ti-6Al-4V deposited single
tracks, produced with a coaxial nozzle and a Laserline 1.5 kW diode laser. The model is a useful industrial aid
and alternative to finite element methods for selecting the parameters to use for laser direct metal deposition.
Keywords: laser metal deposition, surface cladding, analytical model, iterative model, track geometry

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