An analytical model of the laser clad geometry

Lalas, C.; Tsirbas, K.; Salonitis, Konstantinos; Chryssolouris, George

doi:10.1007/s00170-005-0318-0

Cited by 82 publications

(28 citation statements)

References 24 publications

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“…The multiphysics approach allows for simultaneous solution of multiple phenomena by coupling through a common variable, in this case, temperature. The purpose of the model is to diminish the experimental effort in predicting the geometry and properties of the cladded surface as required by metal processing industry [27]. The last is made possible by solving the model in a reasonably short time.…”

Section: Introductionmentioning

confidence: 99%

Multiphysics simulation of laser–material interaction during laser powder depositon

Vásquez

Ramos‐Grez

Walczak

2011

Int J Adv Manuf Technol

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This work reports a theoretical and numerical study of the parameters related to the process of laser powder deposition through a lateral nozzle. For this purpose, a 3D quasi-stationary finite element model was developed analytically and implemented numerically. The proposed model estimates the shape of the melt pool depending on the process parameters including scanning speed, powder mass flow, laser power, and physical properties. Also, phase transformations and physical properties (density, thermal conductivity, and specific heat) vary as function of temperature. In addition, thermo-capillary forces and their effect on fluid flow inside the melt pool are considered. The obtained set of equations coupled through the temperature variable was solved using COMSOL Multiphysics. The results are presented and compared with previously obtained experimental data, in which chromium powder was deposited, allowing validation of the model. Finally, variations at the melt pool geometry in terms of the operational parameters are analyzed. This model aims at estimation of melt pool geometry during laser powder deposition in time reasonably short to allow for predictable process control.

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Section: Introductionmentioning

confidence: 99%

Multiphysics simulation of laser–material interaction during laser powder depositon

Vásquez

Ramos‐Grez

Walczak

2011

Int J Adv Manuf Technol

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“…Indicative models using an analytical, numerical and experimental approach follow. An analytical approach was made by Lalas et al [82] and Salonitis et al [83] for the calculation of the geometrical characteristics of the produced part. More specifically, the surface tension theory has been applied and geometric relations have been used for the calculation of the following equations, which estimate the geometry of the parts, manufactured via DMD:…”

Section: Dimensional Accuracymentioning

confidence: 99%

“…Reference number KPI Process/Part parameter (Variable) [17][18][19] Etching, deposition, lithography mechanics Surface type, material, shape [32] Residual stresses, distortions [41] System temperature [49] Heat transfer related [50] Part temperature history Layer position in the part under construction [78] Surface finish Melt-pool geometries, layer thickness, powder/laser interaction distance [79] Surface finish, melt pool, dilution ratio Laser power, scanning speed, and powder feed rate [82,83] Clad width, depth and height Process speed, powder feed rate [81] Track and microstructure formation…”

Section: Kpimentioning

confidence: 99%

“…More specifically, modelling of surface roughness is presented in [78] (analytically) and in [79] (numerically). Modelling of topology and dimensional accuracy takes place in [80][81][82][83][84] using analytical, in [85,86] analytical-numerical, in [17][18][19]32,79,[87][88][89][90][91][92][93][94] numerical, whereas in [95] those issues have been empirically modelled utilizing artificial neural networks (ANN). Modelling of the mechanical properties and microstructure has been conducted in [80,81] using analytical, in [86,96] analyticalnumerical and in [94,[97][98][99][100][101] using numerical approaches.…”

Section: Directed Energy Depositionmentioning

confidence: 99%

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Modelling of additive manufacturing processes: a review and classification

Stavropoulos

Foteinopoulos

2018

Manufacturing Rev.

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Abstract. Additive manufacturing (AM) is a very promising technology; however, there are a number of open issues related to the different AM processes. The literature on modelling the existing AM processes is reviewed and classified. A categorization of the different AM processes in process groups, according to the process mechanism, has been conducted and the most important issues are stated. Suggestions are made as to which approach is more appropriate according to the key performance indicator desired to be modelled and a discussion is included as to the way that future modelling work can better contribute to improving today's AM process understanding.

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“…The typical assumptions of an analytical model are quasistationary conditions, a mathematically simple substrate shape (typically semi-infinite or thin plate), and geometrically simple melt pool boundaries, either combinations of half ellipses 34,35 (based on moving source heat theory 36,37 ) or circles 11,38,39 (assuming surface tension normal to the surface shapes the molten pool). Despite these necessary simplifications, there have been some recent informative models and ones covering the effect of powder types and laser focus points on wall layer formation [40][41][42] and on combining laser and induction heating for hybrid rapid cladding 43 stand out.…”

Section: B Models Of the Melt Pool Processmentioning

confidence: 99%

Advances in the modeling of laser direct metal deposition

Pinkerton

2014

Journal of Laser Applications

136

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This paper provides a review of the current state of the art in modeling of laser direct metal deposition and cladding processes and identifies recent advances and trends in this field. The different stages of the process and the features, strengths and weaknesses of models relating to them are discussed. Although direct metal deposition is now firmly in the industrial domain, the benefits to be gained from reliable predictive modeling of the process are still to be fully exploited. The genuine progress there has been in this field in the last five years, particularly in discretized modeling, means modeling cannot be overlooked as an enabling method for academia and industry, but there is still more work to be done.

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An analytical model of the laser clad geometry

Cited by 82 publications

References 24 publications

Multiphysics simulation of laser–material interaction during laser powder depositon

Multiphysics simulation of laser–material interaction during laser powder depositon

Modelling of additive manufacturing processes: a review and classification

Advances in the modeling of laser direct metal deposition

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