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Melt pool turbulence effects on the interface between dissimilar materials maufactured by directed energy deposition with laser and powder

Abstract : Laser powder deposition allows for the manufacturing of multi-metallic near net shape structures, with control over the feedstock composition and intense liquid mixing of elements. To better understand the multi-physical aspects of the melt pool and strive towards local composition prediction, we developed within Comsol Multiphysics® a 3D finite element model of an interface between chromium and stainless steel, with a beam spot size close to 1.3 mm. A modified v2-f model is implemented to investigate the effect of turbulence on heat, momentum, and species transport. To minimize the domain size, the model is constructed in the moving frame of the laser. Overlapping on previous tracks is accounted for by updating the upstream face boundary conditions with the composition and free-surface shape of the calculated molten cross-section. This allows for the fast computation of the steady-state solution of the current pass. Simulation results are compared to the elemental and microstructural analysis of a part containing an interface between chromium and stainless steel manufactured by a controlled atmosphere LENS® system. Mixing effects induced by turbulence thicken the melt pool and homogenizes the core of the melt pool, which is consistent with the experimental results. Nonetheless, chemical heterogeneities can be seen at the interface with the substrate and are reviewed in light of the simulation results.
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https://hal-cea.archives-ouvertes.fr/cea-03412001
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Submitted on : Tuesday, November 2, 2021 - 5:00:07 PM
Last modification on : Friday, November 5, 2021 - 4:14:33 AM

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Vincent Jacquier, Julien Zollinger, Philippe Zeller, Morgan Dal, Frédéric Schuster, et al.. Melt pool turbulence effects on the interface between dissimilar materials maufactured by directed energy deposition with laser and powder. Journal of Materials Engineering and Performance, Springer Verlag/ASM International, 2021, pp.1. ⟨10.1007/s11665-021-06279-x⟩. ⟨cea-03412001⟩

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