Thermo-mechanical Analysis of Scan Strategy on Laser Directed Energy Deposition of Copper on SS316

Bi-metallic components with diverse properties are crucial in enhancing functionality in high-temperature applications, such as in aircraft, boilers, and nuclear reactors. Hybrid configurations, specifically copper-steel (SS316) combinations, are gaining attention for their improved thermal conductivity and high strength, making them desirable for enhanced thermal performance. However, the challenge lies in effectively cladding copper onto SS316 through laser-directed energy deposition (L-DED), given the dissimilarities in their thermo-physical properties, leading to residual stress and distortion. In this study, we conduct a one-way coupled thermo-mechanical analysis using the Finite Element Method (FEM), with SS316 steel as the substrate and copper as the deposited part. The analysis explores six different scanning patterns: raster, zig-zag, alternate line, out-in spiral, in-out spiral, and a novel S scan. The findings offer valuable insights into effective scanning strategies for dissimilar bi-metallic cladding, aiming to minimize residual stresses and deflections. Subsequently, the effect of preheat temperature on the residual stress and deflections are studied for different scanning strategy.