Numerical Simulation and Analysis of Metal Fused Coating Forming

Abstract

3D printing has been widely used for the forming of functional parts, and electron beam and laser are used as the heat source mostly, which is expensive and energy consuming [1]. Metal Fused coating process is a developing additive manufacturing technology, the high power heat source is eliminated and the material is not confined to powder and wire [2]. In this paper, computational fluid dynamics method [3] combined with fluid volume method are used to study the influence of process parameters on coating and morphology. Considering the material’s thermal physical properties change with temperature, the temperature history of feature positions and three-dimensional morphology are analysed. It is found that the differences of the melt spreading temperature histories of three key positions increase with the printing speed. The influence rules of different layer thickness and ratios of feeding speed to nozzle moving speed on bonding width, single-layer width and the ratio of bonding width to single-lane width are gained, which provides guidance to select the parameters in given process conditions.