Numerical Simulation on Effects of Spatial Laser Beam Profiles on Heat Transport During Laser Directed Energy Deposition of 316L Stainless Steel
Received date: 2022-10-12
Revised date: 2022-11-04
Online published: 2023-03-28
Supported by
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)
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.
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[J]. Acta Metall Sin, 2024 , 60(12) : 1678 -1690 . DOI: 10.11900/0412.1961.2022.00509
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