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Modeling forced convection in the thermal simulation of laser cladding processes

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Abstract

A comprehensive methodology for the implementation of thermal convection into the finite element (FE) analysis of laser direct energy deposition (DED) cladding is developed and validated. Improved convection modeling will produce improved thermal simulations, which will in turn yield more accurate results from subsequent models seeking to predict microstructural changes, deformation, or residual stresses. Two common convection implementations, considering no convection or free convection only, are compared to three novel forced convection methods: forced convection from heat transfer literature, forced convection from lumped capacitance experiments, and forced convection from hot-film anemometry measurements. During the cladding process, the exposed surface, the surface roughness, and total surface area change due to material deposition. The necessity of accounting for the evolution of the mesh surface in the FE convection model is investigated. Quantified error analysis shows that using any of the three forced convection methodologies improves the accuracy of the numerical simulations. Using surface-dependent hot-film anemometry measured convection yields the most accurate temperature history, with L 2 norm errors of 6.25−22.1 ∘C and time-averaged percent errors of 2.80–12.4 %. Using a physically representative convection model applied to a continually evolving mesh surface is shown to be necessary for accuracy in the FE simulation of laser cladding processes.

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Authors and Affiliations

  1. The Pennsylvania State University, 17 Reber Building, University Park, PA, 16802, USA

    Michael F. Gouge & Jarred C. Heigel

  2. The Pennsylvania State University, 232 Reber Building, University Park, PA, 16802, USA

    Panagiotis Michaleris

  3. The Pennsylvania State University, 4410D Applied Science Building, University Park, PA, 16802, USA

    Todd A. Palmer

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  1. Michael F. Gouge
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  2. Jarred C. Heigel
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  3. Panagiotis Michaleris
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  4. Todd A. Palmer
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Correspondence to Michael F. Gouge.

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Gouge, M.F., Heigel, J.C., Michaleris, P. et al. Modeling forced convection in the thermal simulation of laser cladding processes. Int J Adv Manuf Technol 79, 307–320 (2015). https://doi.org/10.1007/s00170-015-6831-x

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  • DOI: https://doi.org/10.1007/s00170-015-6831-x

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