Mechanical engineering
Modeling wire fusion to optimize bead production in DED-LHW additive manufacturing
Published on - 14th CIRP Conference on Photonic Technologies
Mastering material deposition in DED-LHW additive manufacturing and determining process parameters relies mainly on costly experimental campaigns. Numerous tests are required to identify the parameters (laser power, intensity, wire speed, and feed rate) that enable the production of defect-free welds. In this article, a laser wire-fusion model is proposed that accounts for the combined effects of the laser source and the Joule effect in preheating the wire. The model is validated through wire-fusion experiments in a coaxial configuration with three laser beams for IN718. The model is then validated by manufacturing welds and classifying them according to a typology of defects observed during production (sound, dripping, or stubbing). The model is sufficiently generic to be applied to any material and to coaxial configurations with more beams.