Numerical modelling of heat transfer, mass transport and microstructure formation in a high deposition rate laser directed energy deposition process

In laser directed energy deposition (L-DED) processes, by applying a converged powder stream, relatively high laser power and larger laser spot, the powder utilisation efficiency and processing speed can be increased. There is, however, lack of mathematical models for L-DED. In this paper, a three-dimensional numerical model is established to study the mass transport and heat transfer in the melt pools in high deposition rate (HDR) L-DED of 316L stainless steel. The Volume of Fluid (VOF) method is employed to track the melt pool free surfaces, and enthalpy-porosity method is used to model the solid-liquid phase change. A discrete powder source model is developed by considering the non-uniform powder feed rate distribution. Results show that this model can well predict the deposited track dimensions (width, height and dilution depth). Different from conventional L-DED processes, the impact of higher mass addition on the melt pool fluid flow and temperature distribution is significant. In the regions where filler powder is injected, a downward mass flow is observed, and the temperature is slightly reduced. With the extracted temperature distribution and geometry at the solidification front, the solidification conditions are also calculated, as well as the primary dendrite arm spacing (PDAS) of the solidified tracks. Due to the high laser energy input, the temperature gradient is lower, and coarser microstructures are formed compared with conventional L-DED. The simulated results are in good agreement with experimental results.