High fidelity model of directed energy deposition: Laser-powder-melt pool interaction and effect of laser beam profile on solidification microstructure

SA Khairallah, EB Chin, MJ Juhasz, AL Dayton… - Additive …, 2023 - Elsevier
Metal additive manufacturing technologies keep receiving a great deal of interest as well as
strong requests to develop methods to link the process science to printed parts performance …

Solidification in metal additive manufacturing: challenges, solutions, and opportunities

S Chandra, J Radhakrishnan, S Huang, S Wei… - Progress in Materials …, 2024 - Elsevier
The physics of alloy solidification during additive manufacturing (AM) in methods such as
laser powder bed fusion (LPBF), electron beam powder bed fusion (EPBF), and laser …

Rapid prediction of real-time thermal characteristics, solidification parameters and microstructure in laser directed energy deposition (powder-fed additive …

Y Huang, M Ansari, H Asgari, MH Farshidianfar… - Journal of Materials …, 2019 - Elsevier
The localized thermal characteristics, solidification parameters and the corresponding
microstructure depend highly on the process parameters in the laser powder-fed additive …

Microscale interaction between laser and metal powder in powder-bed additive manufacturing: Conduction mode versus keyhole mode

H Wang, Y Zou - International Journal of Heat and Mass Transfer, 2019 - Elsevier
Metal additive manufacturing (AM) techniques, particularly laser powder-bed methods, have
shown tremendous advantages for producing high-value, complex, and customized …

Physics-based thermal-chemical-fluid-microstructure modelling of in-situ alloying using additive manufacturing: Composition-microstructure control

J Shinjo, A Kutsukake, A Arote, YT Tang… - Additive …, 2023 - Elsevier
Nucleation and grain growth during metal additive manufacturing (AM) still remain
debatable since the nature of rapid melting and solidification induced by laser-powder …

Leveraging the digital thread for physics-based prediction of microstructure heterogeneity in additively manufactured parts

GL Knapp, B Stump, L Scime, AM Rossy, C Joslin… - Additive …, 2023 - Elsevier
A major limitation of additive manufacturing (AM) processes is that local conditions of
material deposition frequently lead to unintentional heterogeneities in microstructure and …

In-situ experimental and high-fidelity modelling tools to advance understanding of metal additive manufacturing

L Wang, Q Guo, L Chen, W Yan - International Journal of Machine Tools …, 2023 - Elsevier
Metal additive manufacturing has seen extensive research and rapidly growing applications
for its high precision, efficiency, flexibility, etc. However, the appealing advantages are still …

Model-driven directed-energy-deposition process workflow incorporating powder flowrate as key parameter

KD Traxel, D Malihi, K Starkey, A Bandyopadhyay - Manufacturing Letters, 2020 - Elsevier
Process optimization for directed-energy-deposition, an industrial laser-based additive
manufacturing technique, is a time-intensive endeavor for manufacturers. Herein we …

[HTML][HTML] Multi-phase flow simulation of powder streaming in laser-based directed energy deposition

L Wang, S Wang, Y Zhang, W Yan - International Journal of Heat and Mass …, 2023 - Elsevier
As a promising additive manufacturing technique, laser-based directed energy deposition
has been widely applied in part fabrication, surface cladding, and part restoration. During …

Controlling grain nucleation and morphology by laser beam shaping in metal additive manufacturing

TT Roehling, R Shi, SA Khairallah, JD Roehling… - Materials & Design, 2020 - Elsevier
Gaussian laser intensity profiles are standard in laser-based metal additive manufacturing,
although recent work in single-layer melt tracks showed that beam shaping could offer a …