Numerical Simulation on Effects of Spatial Laser Beam Profiles on Heat Transport During Laser Directed Energy Deposition of 316L Stainless Steel

doi:10.11900/0412.1961.2022.00509

Acta Metall Sin

2024, Vol. 60

Issue (12): 1678-1690 DOI: 10.11900/0412.1961.2022.00509

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Numerical Simulation on Effects of Spatial Laser Beam Profiles on Heat Transport During Laser Directed Energy Deposition of 316L Stainless Steel

REN Song¹, WU Jiazhu¹(

), ZHANG Yi², ZHANG Dabin¹, CAO Yang¹, YIN Cunhong¹

1 School of Mechanical Engineering, Guizhou University, Guiyang 550025, China
2 College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, China

Cite this article:

REN Song, WU Jiazhu, ZHANG Yi, ZHANG Dabin, CAO Yang, YIN Cunhong. Numerical Simulation on Effects of Spatial Laser Beam Profiles on Heat Transport During Laser Directed Energy Deposition of 316L Stainless Steel. Acta Metall Sin, 2024, 60(12): 1678-1690.

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Abstract

The distribution characteristics and magnitude of energy density on the cross section of a laser beam are determined by its spatial profile, which directly impacts heat transport during laser material processing. Hence, it is essential to understand the influence of spatial profiles on heat transport during laser directed energy deposition with synchronous material delivery. Herein, a three-dimensional heat transport model that takes into account important physical events such as laser-powder-pool coupling, thermal-fluid coupling, solid-liquid phase change, and multiple heat transfer was established. The model was validated using single-track single-layer deposition experiments. The effects of four spatial laser beam profiles, including Gaussian (GP), super-Gaussian (SGP1 and SGP2), and pure flat-topped (FTP) profiles, on the heat transport and fluid flow within the molten pool were investigated. Simulated results show that peak temperatures of the molten pool decrease sequentially under GP, SGP1, SGP2 and FTP, and the temperature gradients on the solidification interface increase gradually from the top to the bottom of the molten pool. Temperature gradients on the solidification interface positively correlate with the angle between the normal direction of the solidification interface and the laser scanning direction, and negatively correlate with the distances from the beam center on the molten pool surface. Under all four spatial laser beam profiles, temperature gradients at the same positions on the solidification interface near the rear of the molten pool increase, while those at the bottom of the molten pool decrease. The molten pool exhibits an outward annular flow pattern under all four spatial laser beam profiles with fluid flows mainly driven by Marangoni shear stress. Heat transfer within the molten pool is dominated by Marangoni convection and heat conduction. Average fluid velocities within the molten pool decrease successively according to the following order: Gaussian, super-Gaussian, and pure flat-topped profiles.

Key words: laser directed energy deposition spatial profile 316L stainless steel heat transport numerical simulation

Received: 12 October 2022

ZTFLH:

TG142.3

Fund: National Natural Science Foundation of China(51975205);Guizhou Provincial Science and Technology Projects([2021]265);Guizhou Provincial Science and Technology Projects([2023]017);Natural Science Foundation of Guizhou University((2021)15);Guizhou University Graduate Innovative Talent Program Project(202203)

Corresponding Authors: WU Jiazhu, associate professor, Tel: (0851)83627516, E-mail: wujz_pillar@163.com

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	REN Song
	WU Jiazhu
	ZHANG Yi
	ZHANG Dabin
	CAO Yang
	YIN Cunhong

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00509 OR https://www.ams.org.cn/EN/Y2024/V60/I12/1678

Fig.1 Principle schematic of laser directed energy deposition

Fig.2 Schematics of the spatial density distributions of GP (a), SGP1 (b), SGP2 (c), and FTP (d) respectively when the laser power P = 700 W and the beam radius r_b = 1.2 mm (GP—Gaussian profile, SGP—super-Gaussian profile, FTP—flat-topped profile)

Fig.3 Schematic of the coordinate systems { O }, { L }, and {iPS} of the coaxial powder stream (The injection angle φ refers to the angle between the axis z_i_PS of the powder stream component and the laser axis z_L; the divergence angle θ is the angle between the axis z_i_PS and boundary of the powder stream component; R_in is the distance from the intersection point O_S of the extended powder stream component to the laser axis z_L)

Fig.4 Meshing of 3D deposition model (unit: mm)

Physical parameter	Value	Unit	Ref.
Solidus temperature T_sol	1648	K
Liquidus temperature T_liq	1673	K
Solid specific heat c_sol	604	J·kg^-1·K^-1
Liquid specific heat c_liq	824	J·kg^-1·K^-1
Solid thermal conductivity k_sol	25	W·m^-1·K^-1
Liquid thermal conductivity k_liq	36	W·m^-1·K^-1
Room temperature T_ref	293.15	K
Solid density ρ_sol	8000	kg·m^-3
Liquid density ρ_liq	6893	kg·m^-3
Emissivity $ε$	0.7		[26]
Laser absorptivity $η$	0.38
Latent heat of fusion L	2.5 × 10⁵	J·kg^-1	[29]
Convective heat transfer coefficient h_con	80	W·m^-2·K^-1	[30]
Thermal expansion coefficients α_exp	5.85 × 10^-5	K^-1	[31]
Dynamic viscosity μ	6 × 10^-3	kg·m^-1·s^-1	[32]
Permittivity of vacuum σ'	5.67 × 10^-8	W·m^-2·K^-4

Table 1 Parameter values of the thermal transfer model

Physical module	Boundary
	Top surface	Other sectional surface
	Top surface	Other sectional surface
Heat transfer	$T r e f = 293.15 K$	$T r e f = 293.15 K$
Fluid flow	$u 0 = 0$	$u 0 = 0$
	$P 0 = 0$	$P 0 = 0$
Moving mesh	$V L / G 0 = 0$	$d x, d y, d z = 0$

Table 2 Initial values used in the simulation

Fig.5 Single-track single-layer deposition experiment

Table 3 Process parameters of the deposition experiment

Fig.6 Experimental and simulated results at laser powers of 600 W (a), 700 W (b), and 800 W(c) under the action of SGP1

Table 4 Characteristic parameters of molten pool at laser powers of 600, 700, and 800 W under the action of SGP1

Fig.7 Temperature (T) fields of molten pool under actions of GP (a), SGP1 (b), SGP2 (c), and FTP (d)

Fig.8 Temperature distributions of trajectory 1 in Fig.4 under the four spatial laser beam profiles

Fig.9 Temperature gradient of longitudinal slice of molten pool under GP

Fig.10 Temperature gradient distributions on two longitudinal sections α (a) and β (b) under GP

Fig.11 Temperature gradients at the observation points on the solidification boundary of the α-plane (a) and β-plane (b) under the four spatial laser beam profiles

Fig.12 Distances from the observation points on the solidification boundary of α-plane (a) and β-plane (b) to the beam center of the molten pool surface under the four spatial laser beam profiles

Fig.13 Angles between the laser scanning direction and the normal direction at the observation points on the solidification boundary of α-plane (a) and β-plane (b) under the four spatial laser beam profiles

Fig.14 Velocity fields of molten pool under actions of GP (a), SGP1 (b), SGP2 (c), and FTP (d)

Fig.15 Velocity distributions of trajectory 1 in Fig.4 under the four spatial laser beam profiles

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