Towards hybrid laser-arc based directed energy deposition: Understanding bead formation through mathematical modeling for additive manufacturing

This study highlights three phenomena in directed energy deposition using hybrid laser-arc: bead formation, change the shape because of laser-arc interaction, and formation defects. Unlike arc-based deposition, differs from pre-conceived parabolic or cosine form, which necessitates a new model. The laser-induced flow preheating wire electrode widen molten pool width cause depression top surface deposited bead. Consequently, fixed critical offset distance for multi-pass (e.g., 0.66 0.73 times width, based on flat tangent overlapping model deposition) does not yield optimal deposition. In this work, first, parametric assesses defect phenomenon high-strength steel as candidate material, followed by an evaluation existing models appropriateness defect-free beads. Results indicate that parabola composited with unimodal beta distribution - accounts laser influence (power distance) is more responsive to variation substantially accurate than models. Increasing power significantly changes reduces distance. traverse speed most factor welding current leading It envisioned fundamental understanding developed result present investigation will provide direction additive manufacturing several material classes, many are weldable therefore additively manufactured