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Wednesday, June 25, 2008 - 10:30 AM

Use of 3-D Simulation to Control Melt Pool Size and its Temperature in Complex Deposits with Laser Additive Manufacturing

A. B. Chaudhary, M. Keller, Applied Optimization, Inc., Dayton, OH

<>Control of melt pool size and its temperature is important to attaining consistent solidification conditions in laser additive manufacturing. The laser power and speed that will result in such consistency is unknown a priori because the temperature field evolves continuously during the deposition and the geometry of the deposit can vary from one location to another. This paper describes a hands-off automated simulation of laser additive manufacturing. It is developed to solve for the laser power and velocity conditions that control melt pool size and its temperature to user-specified values under complex deposit conditions. The solution outputs the evolving temperature and stress fields as the deposit progresses. It also computes the thermal gradient and velocity of the solidification front for the purpose of correlation with resulting microstructure.  Sample solutions will be presented.


Summary: This paper describes a hands-off automated simulation of laser additive manufacturing. It is developed to solve for the laser power and velocity conditions that control melt pool size and its temperature to user-specified values under complex deposit conditions.