Modeling the Effect of Spherical Particles of various sizes using Direct Laser Deposition

Abstract

Additive manufacturing (AM) is the systematize name to describe the new world of manufacturing technology that built 3D objects by adding materials in layers, whether the material is in plastic, ceramics, metal and or it is advancing towards human tissues. Additive manufacturing (AM) technique of direct laser deposition (DLD) allows quick fabrication of fully-dense metallic components directly from Computer Aided Design (CAD) solid models. Direct Laser deposition (DLD) is ever-increasing in modern advanced manufacturing field for rapid manufacturing, tooling repair or surface enhancement of the critical metal components. DLD is based on a kind of directed energy deposition (DED) technology which ejects a strand of metal powders into a moving molten pool caused by energyintensive laser to finally generate the solid tracks on the work piece surface. This method has a great possibility to reduce material waste through near net shape production as well as adding value to an already manufactured costly component (aviation and aerospace industry).The purpose of this study is to investigate the effect different size of spherical shape powder will have in direct energy deposition (DED).Powder size plays important role in determining the height, width of each track. Proposed modeling considerations and a specific CFD model of powder feeding will assist in accurately simulating the DED process. The results of these investigations have also been validated with an experimental work.