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Modeling of the laser powder–based directed energy deposition process for additive manufacturing: a review

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Abstract

Laser powder–based directed energy deposition (DED) is a specific additive manufacturing process that offers an effective way to fabricate parts via simultaneous delivery of powders and laser beam. It has been developing greatly in the recent decades and being widely used for manufacturing, prototyping, and repairing. Complex physical events take place during the manufacturing process and have great impacts on its overall performance. To build high-quality parts through the laser powder–based DED process, its physical insights and process parameters need to be understood and optimized, for which modeling provides an efficient way. This article gives a review of the modeling work for the laser powder–based DED process, in which the models developed for powder stream and its interaction with laser beam, melt-pool, and bulk heating are discussed in detail. Different modeling approaches and methods towards overall and specific physical processes of the laser powder–based DED are analyzed and compared. Suggestions towards the modeling are also given at the end.

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Funding

This research was supported by the Natural Sciences and Engineering Research Council of Canada (NSERC) Collaborative Research and Development Grant, CRDPJ 479630. The lead author also receives partial funding from NSERC Collaborative Research and Training Experience Program Grant, CREATE 449343. The author would also like to thank the McGill Engineering Doctoral Award (MEDA).

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Guan, X., Zhao, Y.F. Modeling of the laser powder–based directed energy deposition process for additive manufacturing: a review. Int J Adv Manuf Technol 107, 1959–1982 (2020). https://doi.org/10.1007/s00170-020-05027-0

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