Mesoscale modelling of Directed Energy Deposition process
With Gabriele Piscopo
Among the various metal Additive Manufacturing (AM) technologies currently available on the market, Directed Energy Deposition (DED) processes are particularly advantageous for the production of large metal components and for the possibility of adding material to an existing part. In the laser DED process, higher deposition rates than laser powder bed fusion processes are obtained, using higher laser power and setting layer thickness up to five times greater. However, thick layers adversely affect the adhesion between layers, because the depth of melt into the substrate may not to be sufficient. Finite Element (FE) analyses are commonly used to study thermal phenomena under simple assumptions and to consequently forecast process results as a function of process parameters without making an expensive and long experimental campaign.
In this research seminar the main phenomena of DED process are analyzed and a novel FE model is presented. Results show that the proposed model is able to predict if a specific set of process parameters guarantees adequate adhesion between the fed material and the substrate. Additionally, the proposed numerical model is validated against experimental data from the literature in order to evaluate the estimation capability to forecast the penetration depth. The comparison between the numerical and the experimental results shows a good agreement with differences in the measure of the penetration depth of about 14%.
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