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Experimental and Numerical Study of Heat Transfer in Thin-Walled Structures Built by Direct Metal Deposition and Geometry Improvement via Laser Power Modulation

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Abstract

Direct metal deposition (DMD) is a method of additive manufacturing in which parts are manufactured layer by layer by melting powder particles, carried in a stream of gas to the working area by using a laser beam. Due to the layer wise nature of the process, heat eventually builds up inside a part, leading to increased temperatures and melt pool volumes in the working area. This effect is especially prominent in thin single-pass wall structures, which leads to a deformation of geometry or, in extreme cases, to a complete failure of a build. In this paper, a numerical simulation of the thermal behavior of thin-walled structures made from 316L stainless steel by direct metal deposition method with variable and constant laser power was performed. The work is carried out to study the effect of the number of deposited metal layers and their radius of curvature on thermal fields distribution in the workpiece and the resulting geometry of the part. Dependencies of the molten pool volume on the number of layers and a radius of curvature of thin walls have been established. To stabilize the wall thickness of parts, polynomial equations relating laser power input and radius of curvature to layer number are obtained. By modulating the laser power, it is possible to maintain the same volume of the molten pool in each layer, and at different radiuses of curvature, which favorably affects the uniformity of the thickness of thin walls. An analysis of the geometry of obtained samples is carried out, results of which are consistent with the simulation results. It has been established that the use of a variable power of laser radiation when growing thin walls makes it possible to reduce the roughness of their lateral surface by more than 2 times.

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Acknowledgements

The authors express their gratitude for the equipment and materials provided to them by Science Educational Centre “Additive Manufacturing Centre” and Ltd “Moscow center of laser technologies”.

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Authors and Affiliations

  1. Department of Engineering Technology, Bauman Moscow State Technical University Moscow, Moscow, Russia, 105005

    Zahra Mianji, Andrey Kholopov, Ivan Binkov & Kuzma Klimochkin

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  1. Zahra Mianji
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  2. Andrey Kholopov
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  3. Ivan Binkov
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  4. Kuzma Klimochkin
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Contributions

All authors contributed to the study conception and design. Material preparation, simulation model, experimental procedures and primary data collection and analysis were performed by [Zahra Mianji], [Ivan Binkov]. The first draft of the manuscript was written by [Zahra Mianji], revised manuscript was written by [Ivan Binkov], all authors commented on previous of the manuscript. Consultation and guidance were given by [Andrey Kholopov]. Additional surface roughness measured were performed by [Kuzma Klimochkin]. All authors read and approved the final manuscript.

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Correspondence to Zahra Mianji.

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Mianji, Z., Kholopov, A., Binkov, I. et al. Experimental and Numerical Study of Heat Transfer in Thin-Walled Structures Built by Direct Metal Deposition and Geometry Improvement via Laser Power Modulation. Lasers Manuf. Mater. Process. 10, 353–372 (2023). https://doi.org/10.1007/s40516-023-00211-y

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