Abstract
Abstract Layer by layer deposition in laser based metal additive manufacturing process causes accumulation of high thermal residual stresses. This may sometimes lead to dimensional inaccuracy and warping of the deposited clad layer. Additive manufacturing being expensive process, simulation may reduce the number of experimental trails. In the present work, 2D thermal model of Direct Metal Laser Deposition process taking Inconel 718 as deposited material was solved using the finite element software package COMSOL MULTIPHYSICS and the phase change of the material was incorporated. The thermal model is carried out for a 2D single clad bead to estimate HAZ and melt depth. The proposed 2D thermal model can predict the melt pool boundary at the interface of the clad layer and the substrate as a function of time for a given set of laser process parameters and found to be in good agreement with the experimental results.
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