Numerical modelling and parametric investigation for the laser wire-feeding direct energy deposition

A computational framework that can be implemented into a two-phase flow model has been developed for the DED (direction energy deposition) process. Computational Fluid Dynamics (CFD) techniques, including continuity, momentum, heat transfer, and volume of fluid (VOF) method, have been integrated to investigate the wire-feeding type DED (direction energy deposition) process. The influence of Marangoni and recoil force on the size of the final cladding geometry has been studied through the fluid flow and heat transfer within the melting pool. We have further utilized the CFD results to investigate the trends of output parameters, such as cladding height, width, and dilution in terms of working conditions, including wire-feeding mass flow rate, laser power, and scanning speed. Besides, we applied a statistical approach to experiment data and verified the trends observed from CFD investigations. This study provides a reliable numerical model and brings further insightful information on the interaction between the working conditions and final track geometry, which benefits the development of design guidelines for the related industries.