An Improved Finite Element Based Approach to Predict Single Track Geometry During Laser Directed Energy Deposition

Abstract

This paper reports development of a two-dimensional transient finite element based numerical model to predict dimensions of deposited single track during laser directed energy deposition (LDED) of Inconel 625 (IN625) superalloys. The numerical model in the paper is based on two steps where first melt pool dimensions are determined using a transient thermal simulation. The second step accounts for the material addition, where the elements are activated based on the calculation of excess enthalpy. The numerical model is based on the fundamental principles of energy and mass balance. The numerical model also incorporates the fluid dynamics effects by multiplying the correction factor to the thermal conductivity of the material above melting temperature and also compares the track dimensions without considering the correction factor. A comparison of the track height and width obtained from the numerical model at C<inf>f</inf> = 1 and 2.5 with experimental measurements was done. The maximum absolute percentage error in the numerical model considering the fluid dynamics effects (C<inf>f</inf> = 2.5) is 5% in track height and 9% in track width. The percentage errors in the case of numerical model without fluid dynamics effects (C<inf>f</inf> = 1) is 13% in track height and 16% in track width. The numerical model without considering the fluid dynamics effect is found to overpredict the track dimensions in all the cases. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.