Melt Pool Turbulence Effects on the Interface between Dissimilar Materials Manufactured by Directed Energy Deposition with Laser and Powder

Directed energy deposition (DED) with laser and powder allows the manufacturing of multi-metallic near net shape structures, control over feedstock composition intense liquid mixing elements. To better understand multi-physical aspects melt pool strive toward local prediction, a 3D finite element model chromium on stainless steel has been developed. A modified v2-f is implemented to investigate effect turbulence heat, momentum, mass transport. The formulated in moving frame laser, which reducing domain size computation time. Overlapping previous tracks included by updating upstream face boundary conditions free-surface calculated molten cross section. This for fast steady-state solution layer formation. Simulation results are compared analysis part containing an interface between manufactured using controlled atmosphere powder-DED system. diffusive effects induced analyzed regard laminar simulation found have significant impact maximum fluid velocity temperature. Melt thickens flow vortices homogenizes core pool, consistent experimental results. Chemical heterogeneities can be seen at substrate reviewed light