Numerical Investigation of Laser Deposited Al-Based Coatings on Ti-6Al-4V Alloy

Titanium Alloy (Ti6Al4V) opened a wide range of useful applications in aerospace industries; these industries make use of different additive manufacturing (AM) techniques to obtain parts of different properties for different uses by this titanium alloy. Ttitanium alloy mainly stands out due to the properties such as high specific strength to weight ratio, and excellent corrosion resistance. Despite these benefits, the formation of defects such as pores and cracks play a vital role in the quality of the deposited coatings. The presence of these unwanted artefacts on laser deposited coatings depends on the melting, cooling and solidification of the melt pool. In this research, a simulation of the heat transfers and fluid dynamics of the melt pool is developed to predict the process parameters and reinforcement proportions on the clad geometry quality. The results were compared to the experimental results for confirmation and validation. Numerical modelling using COMSOL multiphysics 5.2 revealed the thermal behaviour of the coated samples.