Laser-based additive manufacturing (LBAM) processes can be utilized to generate functional parts (or prototypes) from the ground-up via layer-wise cladding – providing an opportunity to generate complex-shaped, functionally graded or custom-tailored parts that can be utilized for a variety of engineering applications. Directed Energy Deposition (DED), utilizes a concentrated heat source, which may be a laser or electron beam, with in situ delivery of powder- or wire-shaped material for subsequent melting to accomplish layer-by-layer part fabrication or single-to-multi layer cladding/repair. Direct Laser Deposition (DLD), a form of DED, has been investigated heavily in the last several years as it provides the potential to (i) rapidly prototype metallic parts, (ii) produce complex and customized parts, (iii) clad/repair precious metallic components and (iv) manufacture/repair in remote or logistically weak locations. DLD and Powder Bed Fusion-Laser (PBF-L) are two common LBAM processes for additive metal part fabrication and are currently demonstrating their ability to revolutionize the manufacturing industry; breaking barriers imposed via traditional, ‘subtractive’ metalworking processes. This article provides an overview of the major advancements, challenges and physical attributes related to DLD, and is one of two Parts focused specifically on DLD. Part I (this article) focuses on describing the thermal/fluidic phenomena during the powder-fed DLD process, while Part II focuses on the mechanical properties and microstructure of parts manufactured via DLD. In this current article, a selection of recent research efforts – including methodology, models and experimental results – will be provided in order to educate the reader of the thermal/fluidic processes that occur during DLD, as well as providing important background information relevant to DLD as a whole. The thermal/fluid phenomena inherent to DLD directly influence the solidification heat transfer which thus impacts the part's microstructure and associated thermo-mechanical properties. A thorough understanding of the thermal/fluid aspects inherent to DLD is vital for optimizing the DLD process and ensuring consistent, high-quality parts.

An overview of Direct Laser Deposition for additive manufacturing; Part I: Transport phenomena, modeling and diagnostics

Effect of a magnetic field on free convection in a rectangular enclosure

The solution of a traveling distributed heat source on a semi-infinite plate provides information about both the size and the shape of arc weld pools. The results indicate that both welding process variables (current, arc length and travel speed) and material parameters (thermal diffusivity) have significant effects on weld shape. The theoretical predictions are compared with experimental results on carbon steels, stainless steel, titanium and aluminum with good agreement. 25 references, 23 figures, 1 table.

Temperature fields produced by traveling distributed heat sources

Computational flow modelling and design of bubble column reactors

Buoyancy driven convection in a rectangular enclosure with a transverse magnetic field

The effect of an externally imposed magnetic field on buoyancy driven flow in a rectangular cavity

An experimental and theoretical study of gas bubble driven circulation systems

A mathematical model was developed to account for convection and temperature distributions in stationary arc weld pools driven by buoyancy, electromagnetic and surface tension forces. It is shown that the electromagnetic and surface tension forces dominate the flow behavior. In some cases, these forces produce double circulation loops, which are indirectly confirmed by experimental measurements of segregation in the weld pool. It is also shown that the surface tension driven flows are very effective in dissipating the incident energy flux on the pool surface which, in turn, reduces the vaporization from the weld pool.

Convection in arc weld pools

A mathematical model was developed to predict the velocity and temperature fields in a free plasma jet issuing from a D.C. plasma torch. It was assumed that the temperature and velocity at the torch nozzle were specified and the turbulent Navier-Stokes equations were solved in conjunction with a two-equation model of turbulence and the energy transport equation. The model was formulated in terms of the two-dimensional elliptic equations to facilitate its future extension to nonparabolic problems. The predictions of the model were compared with experimental measurements obtained from laser Doppler and spectroscopic techniques. Good overall agreement was found between the theoretical predictions and the experimental measurements for two sets of initial conditions corresponding to nitrogen/hydrogen and argon/hydrogen plasmas. Radiation was found to have a small effect on the overall heat transfer process, and it is suggested that the assumption of an optically thin radiation loss per unit volume is sufficiently accurate for most engineering applications. The significance of this work lies in the fact that, for the first time, it is possible to test the assumptions of the current model against a reliable set of experimental measurements.

J. Szekely

Papers

The effect of an externally imposed magnetic field on buoyancy driven flow in a rectangular cavity

An experimental and theoretical study of gas bubble driven circulation systems

Convection in arc weld pools

Temperature and velocity fields in a gas stream exiting a plasma torch. A mathematical model and its experimental verification

The transient behavior of weldpools with a deformed free surface