Real-time prediction of dilution for automated laser powder deposition process

Abstract

This paper presents a mathematical model for the real-time monitoring of the dilution in the laser powder deposition process. The proposed model predicts the melt pool depth and dilution as a function of clad height and clad width which in practice can be measured by a vision system. The model is based on the solution of heat diffusion equation using the solution of the heat diffusion due to a point heat source and the superposition principle. Numerical and experimental analyses show a non-linear behavior of the melt pool depth as a function of scanning speed when the other process parameters are kept constant. Using the model that has been validated by experiments, a combined parameter is introduced. This combined parameter which is a nonlinear function of the laser power, scanning speed and the clad height, has the most correlation with the melt pool depth. The comparisons between the numerical and experimental results show that this model is capable of predicting the characteristics of the laser powder deposition process accurately.This paper presents a mathematical model for the real-time monitoring of the dilution in the laser powder deposition process. The proposed model predicts the melt pool depth and dilution as a function of clad height and clad width which in practice can be measured by a vision system. The model is based on the solution of heat diffusion equation using the solution of the heat diffusion due to a point heat source and the superposition principle. Numerical and experimental analyses show a non-linear behavior of the melt pool depth as a function of scanning speed when the other process parameters are kept constant. Using the model that has been validated by experiments, a combined parameter is introduced. This combined parameter which is a nonlinear function of the laser power, scanning speed and the clad height, has the most correlation with the melt pool depth. The comparisons between the numerical and experimental results show that this model is capable of predicting the characteristics of the laser powder...