Material flow and heat transfer characteristics in flat-top laser composite arc-based directed energy deposition

Abstract

In this study, a novel flat-top laser composite arc-based directed energy deposition process is proposed, and the material flow and heat transfer behaviors are investigated for both arc-only and hybrid flat-top laser modes. Transient CFD models are developed to simulate the energy of the laser and arc using the surface heat source and double-ellipsoid body heat source models, respectively, and validated through experimentation. The results show that the high-temperature metal fluid flows outward from the center of the molten pool and then backward in the front part. The flat-top laser does not alter the flow field pattern but allows for the spread of more hot liquid metal towards the lateral edges. Furthermore, it is discovered that the flat-top laser reduces the contact angle and promotes a stable molten pool temperature.