Skip to main content
SpringerLink
Log in

Effects of heat source type and FE time discretization strategy on predicting temperature histories during laser direct energy deposition process of Fe-based alloys

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this study, the temperature evolutions in the laser direct energy deposition process of Fe-based metallic materials are numerically investigated using the finite element method. The effects of heat input method and the model reduction strategy based on the lumped approach in the simulations were studied numerically. The simulations were carried out following the depositions of single beads, single layers, and multiple layers. The results of the simulations were compared with the temperature evolutions obtained in the experiments as well as the melt pool shapes observed in the experiments. Based on the numerical and experimental results, a numerical modeling strategy is proposed for estimating the temperature distributions in the laser direct energy deposition processes in a time-efficient manner, while maintaining the accuracy of the simulation. The proposed simulation strategy used rough simulation time steps for estimating the overall temperature rise, in addition to using only a few fine simulation time steps for predicting detailed temperature distributions at certain simulation times of interest. The proposed strategy allowed the FE model to reduce calculation time by more than 3.8 times while also accurately simulating the detailed temperature of the region of interest.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22

Similar content being viewed by others

Data availability

The data that support the findings of this study are available from the corresponding authors upon reasonable request.

References

  1. Ansari M, Jabari E, Toyserkani E (2021) Opportunities and challenges in additive manufacturing of functionally graded metallic materials via powder-fed laser directed energy deposition: a review. J Mater Process Technol 294:117117. https://doi.org/10.1016/j.jmatprotec.2021.117117

    Article  Google Scholar 

  2. Wang H, Liu W, Tang Z, Wang Y, Mei X, Saleheen KM, Wang Z, Zhang H (2020) Review on adaptive control of laser-directed energy deposition. Opt Eng 59:1. https://doi.org/10.1117/1.oe.59.7.070901

    Article  Google Scholar 

  3. Baek GY, Shin GY, Lee KY, Shim DS (2019) Mechanical properties of tool steels with high wear resistance via directed energy deposition. https://doi.org/10.3390/met9030282

  4. Oh WJ, Lee WJ, Kim MS, Jeon JB, Shim DS (2019) Repairing additive-manufactured 316L stainless steel using direct energy deposition. Opt Laser Technol 117:6–17. https://doi.org/10.1016/j.optlastec.2019.04.012

    Article  Google Scholar 

  5. Keller T, Lindwall G, Ghosh S, Ma L, Lane BM, Zhang F, Kattner UR, Lass EA, Heigel JC, Idell Y, Williams ME, Allen AJ, Guyer JE, Levine LE (2017) Application of finite element, phase-field, and CALPHAD-based methods to additive manufacturing of Ni-based superalloys. Acta Mater 139:244–253. https://doi.org/10.1016/j.actamat.2017.05.003

    Article  Google Scholar 

  6. Weisz-Patrault D (2020) Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing. Addit Manuf 31:100990. https://doi.org/10.1016/j.addma.2019.100990

    Article  Google Scholar 

  7. Smith J, Xiong W, Cao J, Liu WK (2016) Thermodynamically consistent microstructure prediction of additively manufactured materials. Comput Mech 57:359–370. https://doi.org/10.1007/s00466-015-1243-1

    Article  MATH  Google Scholar 

  8. Zhang W, Fu H, Fan J, Li R, Xu H, Liu F, Qi B (2018) Influence of multi-beam preheating temperature and stress on the buckling distortion in electron beam welding. Mater Des 139:439–446. https://doi.org/10.1016/j.matdes.2017.11.016

    Article  Google Scholar 

  9. Kong F, Kovacevic R (2010) 3D finite element modeling of the thermally induced residual stress in the hybrid laser/arc welding of lap joint. J Mater Process Technol 210:941–950. https://doi.org/10.1016/j.jmatprotec.2010.02.006

    Article  Google Scholar 

  10. Huang Y, Yang LJ, Du XZ, Yang YP (2016) Finite element analysis of thermal behavior of metal powder during selective laser melting. Int J Therm Sci 104:146–157. https://doi.org/10.1016/j.ijthermalsci.2016.01.007

    Article  Google Scholar 

  11. Ha K, Kim T, Baek GY, Jeon JB, Shim DS, Moon YH, Lee W (2020) Numerical study of the effect of progressive solidification on residual stress in single-bead-on-plate additive manufacturing. Addit Manuf 34:101245. https://doi.org/10.1016/j.addma.2020.101245

    Article  Google Scholar 

  12. Toyserkani E, Khajepour A, Corbin S (2004) 3-D finite element modeling of laser cladding by powder injection: effects of laser pulse shaping on the process. Opt Lasers Eng 41:849–867. https://doi.org/10.1016/S0143-8166(03)00063-0

    Article  Google Scholar 

  13. Zhang D, Feng Z, Wang C, Liu Z, Dong D, Zhou Y, Wu R (2017) Modeling of temperature field evolution during multilayered direct laser metal deposition. J Therm Spray Technol 26:831–845. https://doi.org/10.1007/s11666-017-0554-5

    Article  Google Scholar 

  14. Baykasoglu C, Akyildiz O, Candemir D, Yang Q, To AC (2018) Predicting microstructure evolution during directed energy deposition additive manufacturing of Ti-6Al-4V. J Manuf Sci Eng Trans ASME 140:1–11. https://doi.org/10.1115/1.4038894

    Article  Google Scholar 

  15. Zhang L, Reutzel EW, Michaleris P (2004) Finite element modeling discretization requirements for the laser forming process. Int J Mech Sci 46:623–637. https://doi.org/10.1016/j.ijmecsci.2004.04.001

    Article  MATH  Google Scholar 

  16. Irwin J, Michaleris P (2016) A line heat input model for additive manufacturing. J Manuf Sci Eng 138(11):111004. https://doi.org/10.1115/1.4033662

    Article  Google Scholar 

  17. Chiumenti M, Neiva E, Salsi E, Cervera M, Badia S, Moya J, Chen Z, Lee C, Davies C (2017) Numerical modelling and experimental validation in selective laser melting. Addit Manuf 18:171–185. https://doi.org/10.1016/j.addma.2017.09.002

    Article  Google Scholar 

  18. Stender ME, Beghini LL, Sugar JD, Veilleux MG, Subia SR, Smith TR, Marchi CWS, Brown AA, Dagel DJ (2018) A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling. Addit Manuf 21:556–566. https://doi.org/10.1016/j.addma.2018.04.012

    Article  Google Scholar 

  19. Jelinek B, Young WJ, Dantin M, Furr W, Doude H, Priddy MW (2020) Two-dimensional thermal finite element model of directed energy deposition: matching melt pool temperature profile with pyrometer measurement. J Manuf Process 57:187–195. https://doi.org/10.1016/j.jmapro.2020.06.021

    Article  Google Scholar 

  20. Fetni S, Enrici TM, Niccolini T, Tran HS, Dedry O, Duchêne L, Mertens A, Habraken AM (2021) Thermal model for the directed energy deposition of composite coatings of 316L stainless steel enriched with tungsten carbides. Mater Des 204:109661. https://doi.org/10.1016/j.matdes.2021.109661

    Article  Google Scholar 

  21. Fallah V, Alimardani M, Corbin SF, Khajepour A (2011) Temporal development of melt-pool morphology and clad geometry in laser powder deposition. Comput Mater Sci 50:2124–2134. https://doi.org/10.1016/j.commatsci.2011.02.018

    Article  Google Scholar 

  22. Michaleris P (2014) Modeling metal deposition in heat transfer analyses of additive manufacturing processes. Finite Elem Anal Des 86:51–60. https://doi.org/10.1016/j.finel.2014.04.003

    Article  Google Scholar 

  23. Baek GY, Shin GY, Lee KY, Shim DS (2019) Mechanical properties of tool steels with high wear resistance via directed energy deposition. Metals 9(3):282. https://doi.org/10.3390/met9030282

    Article  Google Scholar 

  24. Baek GY, Shin GY, Lee EM, Shim DS, Lee KY, Yoon HS, Kim MH (2017) Mechanical characteristics of a tool steel layer deposited by using direct energy deposition. Met Mater Int 23:770–777. https://doi.org/10.1007/s12540-017-6442-1

    Article  Google Scholar 

  25. Kim TH, Baek GY, Jeon JB, Lee KY, Shim DS, Lee W (2021) Effect of laser rescanning on microstructure and mechanical properties of direct energy deposited AISI 316L stainless steel. Surf Coat Technol 405:126540. https://doi.org/10.1016/j.surfcoat.2020.126540

    Article  Google Scholar 

  26. Luo Z, Zhao YF (2020) Numerical simulation of temperature fields in powder bed fusion process by using hybrid heat source model. Solid Freeform Fabrication 2017: Proceedings of the 28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017 1141–1158

  27. D’Ostuni S, Leo P, Casalino G (2017) FEM simulation of dissimilar aluminum titanium fiber laser welding using 2D and 3D Gaussian heat sources. Metals 7(8):307. https://doi.org/10.3390/met7080307

    Article  Google Scholar 

  28. Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metall Trans B 15:299–305. https://doi.org/10.1007/BF02667333

    Article  Google Scholar 

  29. Roberts IA, Wang CJ, Esterlein R, Stanford M, Mynors DJ (2009) A three-dimensional finite element analysis of the temperature field during laser melting of metal powders in additive layer manufacturing. Int J Mach Tools Manuf 49:916–923. https://doi.org/10.1016/j.ijmachtools.2009.07.004

    Article  Google Scholar 

  30. Ramos D, Belblidia F, Sienz J (2019) New scanning strategy to reduce warpage in additive manufacturing. Addit Manuf 28:554–564. https://doi.org/10.1016/j.addma.2019.05.016

    Article  Google Scholar 

  31. Jin QY, Kang D, Ha K, Yu JH, Lee W (2022) Simulation of annealing process on AISI 316 L stainless steel fabricated via laser powder bed fusion using finite element method with creep. Addit Manuf 60:103255. https://doi.org/10.1016/j.addma.2022.103255

    Article  Google Scholar 

  32. Li R, Jin Y, Li Z, Qi K (2014) A comparative study of high-power diode laser and CO2 laser surface hardening of AISI 1045 steel. J Mater Eng Performance 23(9):3085–3091. https://doi.org/10.1007/S11665-014-1146-X

    Article  Google Scholar 

  33. Tobar MJ, Álvarez C, Amado JM, Ramil A, Saavedra E, Yáñez A (2006) Laser transformation hardening of a tool steel: Simulation-based parameter optimization and experimental results. Surface Coatings Tech 200:6362–6367. https://doi.org/10.1016/J.SURFCOAT.2005.11.067

    Article  Google Scholar 

  34. Trapp J, Rubenchik AM, Guss G, Matthews MJ (2017) In situ absorptivity measurements of metallic powders during laser powder-bed fusion additive manufacturing. Appl Mater Today 9:341–349. https://doi.org/10.1016/J.APMT.2017.08.006

    Article  Google Scholar 

  35. Yin H, Emi T (2003) Marangoni flow at the gas/melt interface of steel. Metal Mater Trans B 34(5):483–493. https://doi.org/10.1007/S11663-003-0015-Z

    Article  Google Scholar 

  36. Ariza EA, Martorano MA, De Lima NB, Tschiptschin AP (2014) Numerical simulation with thorough experimental validation to predict the build-up of residual stresses during quenching of carbon and low-alloy steels. ISIJ Int 54:1396–1405. https://doi.org/10.2355/isijinternational.54.1396

    Article  Google Scholar 

Download references

Funding

This study was supported by Korea Institute of Industrial Technology (JA210007, Development of green-hydrogen production system by alkaline-electrolysis/desalination and core parts). Additional support through the Ministry of Trade, Industry, and Energy (MOTIE) and the Korea Institute for Advancement of Technology (KIAT) through the European International R&D Collaboration (G02P03040000701) is gratefully acknowledged.

Author information

Authors and Affiliations

  1. Korea Institute of Industrial Technology, Yangsan, 50623, Republic of Korea

    Kyeongsik Ha & In-Wook Park

  2. Department of Mechanical Engineering, Pusan National University, Busan, 46241, Republic of Korea

    Kyeongsik Ha & Young Hoon Moon

  3. Division of Mechanical Engineering, Korea Maritime and Ocean University, Busan, 49112, Republic of Korea

    Do-sik Shim

  4. School of Materials Science and Engineering, Pusan National University, Busan, 46241, Republic of Korea

    Wookjin Lee

Authors
  1. Kyeongsik Ha
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Do-sik Shim
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. In-Wook Park
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Young Hoon Moon
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Wookjin Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

KH: investigation, formal analysis, and writing–original draft preparation; D-SS: methodology and investigation; I-WP: conceptualization and methodology; YHM: supervision and writing—reviewing and editing; WL: conceptualization, investigation, and writing—reviewing and editing.

Corresponding authors

Correspondence to Young Hoon Moon or Wookjin Lee.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Supplementary Information

Below is the link to the electronic supplementary material.

Supplementary file1 (MP4 4319 kb)

Supplementary file2 (MP4 9762 kb)

Supplementary file3 (MP4 8159 kb)

Supplementary file4 (DOCX 1041 kb)

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ha, K., Shim, Ds., Park, IW. et al. Effects of heat source type and FE time discretization strategy on predicting temperature histories during laser direct energy deposition process of Fe-based alloys. Int J Adv Manuf Technol 129, 4845–4867 (2023). https://doi.org/10.1007/s00170-023-12541-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12541-4

Keywords

Search

Navigation