Molten Pool Surface Research Articles

Welding Defect Monitoring Based on Multi-Scale Feature Fusion of Molten Pool Videos.

Real-time quality monitoring through molten pool images is a critical focus in researching high-quality, intelligent automated welding. However, challenges such as the dynamic nature of the molten pool, changes in camera perspective, and variations in pool shape make defect detection using single-frame images difficult. We propose a multi-scale fusion method for defect monitoring based on molten pool videos to address these issues. This method analyzes the temporal changes in light spots on the molten pool surface, transferring features between frames to capture dynamic behavior. Our approach employs multi-scale feature fusion using row and column convolutions along with a gated fusion module to accommodate variations in pool size and position, enabling the detection of light spot changes of different sizes and directions from coarse to fine. Additionally, incorporating mixed attention with row and column features enables the model to capture the characteristics of the molten pool more efficiently. Our method achieves an accuracy of 97.416% on a molten pool video dataset, with a processing time of 16 ms per sample. Experimental results on the UCF101-24 and JHMDB datasets also demonstrate the method's generalization capability.

Study on the Influence of Laser Power on the Heat–Flow Multi-Field Coupling of Laser Cladding Incoloy 926 on Stainless Steel Surface

In order to explore the influence of laser power on the evolution of molten pool and convective heat transfer of laser cladding Incoloy 926 on stainless steel surface, a three-dimensional thermal fluid multi-field coupled laser cladding numerical model was established in this paper. The variation of latent heat during solid-liquid phase transformation was treated by apparent heat capacity method. The change in the gas–liquid interface was tracked using the mesh growth method in real time. The instantaneous evolution of temperature field and velocity flow field of laser cladding Incoloy 926 on a stainless steel surface under different laser power was discussed. The solidification characteristic parameters of the cladding layer were calculated based on the temperature-time variation curves at different nodes. The mechanism of the impact of laser power on the microstructure of the cladding layer was revealed. The experiment of laser cladding Incoloy 926 on 316L surface was carried out under different laser power. Combined with the numerical simulation results, the effects of laser power on the geometrical morphology, microstructure and element distribution of the cladding layer were compared and analyzed. The results show that with the increase in laser power, the peak temperature and flow velocity of the molten pool surface both increase significantly. The thermal influence of the molten pool center on the edge is enhanced. The temperature gradient, solidification rate, and cooling rate increased gradually. The microstructure parameters (G/R) are relatively small when the laser power is 1000 W. In the experimental range, the dilution rate and wetting angle of the cladding layer both increase with the increase in laser power. When the laser power is 1000 W, the alloying elements of the cladding layer are more evenly distributed and the microstructure is finer. The experimental results are in good agreement with the simulation results.

Numerical investigation of arc characteristics and metal properties in ELAMF-assisted WAAM with wire retraction

In this study, a multi-physics integrated model of wire arc additive manufacturing (WAAM) with wire retraction and external longitudinal alternating magnetic field (ELAMF) assistance is proposed and validated, and the effect of ELAMF on the arc plasma characteristics and metal properties are systematically and quantitatively investigated. The model comprehensively takes the arc plasma heating, wire dynamic retraction, droplet transfer, the formation and diffusion of metal vapor, the melting and solidification of molten metal, and the stirring effect of ELAMF into account. The simulated results show that ELAMF has compressed the arc morphology, and decreased the temperature, potential, current density and static pressure, which are most pronounced when the wire is at an elevated position and the transient current is at its peak phase. Meanwhile, the formation of low-temperature and low-velocity cavities in the center of arc column are promoted by ELAMF, consequently diminishing the energy transferred from the arc plasma to molten pool through thermal conduction and mitigating the squeezing of the arc plasma on the surface of molten pool. The results also demonstrate that the ELAMF has reduced the temperature gradient of liquid metal inside the molten pool, and intensified the forced convection for the occurrence of multiple circulations.

Plume active control in high-power fiber laser welding based on high-speed shielding gas microbeam

Plume is an inherent physical phenomenon in fiber laser keyhole welding, negatively affecting welding quality. This paper proposes a new type of high-speed shielding gas microbeam (HSGM) based on the limitation of conventional shielding gas regulating plumes. The gas flow characteristics of the HSGM on the molten pool surface were explored using numerical simulation. Then, the coaxial double-layer shielding nozzle was trial-manufactured to clarify the regulation law for the HSGM on the plume. The gas velocity and pressure produced by the HSGM on the molten pool surface were positively correlated with the shielding gas flow rate, and the gas flow pattern was an acute triangle shape. The suitable HSGM can significantly restrain plume formation, improve the weld surface forming quality, increase the weld penetration depth (about 15.4%), and reduce the mass loss of the weld (about 58.7%). The significant blowing pressure effect of HSGM on plumes and splashes was the key to regulating the welding process. Compared with conventional shielding gas, the use of HSGM was significantly reduced.

Nacre-mimetic alternating architecture of Ag[sbnd]SnO2 contact: Highly-efficient synergistic enhancement of in-situ self-repairing erosion resistance and naturally evolving impact resistance

Synergistically enhancing the erosion and impact resistance of contacts poses a significant challenge for cutting-edge electrical equipment. Fortunately, mollusk shells in nature have evolved effective strategies to construct microstructures with superior erosion and impact resistance. Inspired by the structure of nacre, AgSnO2 contact material with hierarchical architectures has been designed and fabricated. The mechanistic link between microstructural evolution and dynamic erosion is studied through experiments combined with Computational Fluid Dynamics (CFD) and Finite Element Method (FEM) simulations. Results show that the reconstructed SnO2 skeleton endowed with a highly continuous and anisotropic ‘flowering'-like structure forms a continuous interpenetrating network with Ag, optimizing the conductive pathways on the molten pool surface. Additionally, the Ag-rich regions in the deeper layers on both sides of the molten pool offers a stable ‘nutrient-supply’ for the continuous ‘flowering’ reconstruction of the skeleton, exhibiting excellent in-situ self-repairing erosion resistance. Benefiting from this synergistic strategy, this skeleton is reconstructed based on its natural structure, which further disperses the stress and deformation concentration while inhibiting interfacial debonding, thereby reducing the formation of cracks and significantly enhancing the impact resistance. This work is expected to breakthrough erosion and impact resistance in extreme condition electrical contact materials through biomimetic microstructure design.

Mantis shrimp appendages-inspired Ag-CuO contact: Synergistically enhancing the erosion and impact resistance via gradient-layered scatter-island/chain-skeleton structure

Materials degradation induced by repeated arc erosion and impact poses a considerable challenge for Ag-based contacts. Fortunately, nature has evolved efficient strategies to construct complex gradient-layered structure that exhibit exceptional erosion and impact resistance. Drawing inspiration by the mantis shrimp appendages, a chain-like CuO nanofibre-reinforced Ag-CuO contact material with a gradient-layered scatter-island/chain-skeleton structure was designed and fabricated. Employing a combined experimental and simulation approach, the evolution of the microstructure during the erosion process was investigated. Results indicated that the interaction between the mantis shrimp appendage-like structure and the chain-like CuO nanofibres effectively suppressed the formation of cracks and pores on the contact surface. Particularly, the scatter-island layer not only played a crucial role in maintaining the viscosity of the molten pool and establishing stable electrical and thermal pathways, but also functioned as a “supplement” to continuously supply a steady source of Ag onto the molten pool surface, effectively promoting CuO skeleton restructuring. Meanwhile, the CuO skeleton diffusive-continuous restructuring of the chain-skeleton layer restricted molten pool flow, significantly enhancing contact erosion resistance. Furthermore, the strong synergistic effect between the gradient-layered structures dispersed stress and deformation concentration on the contact surface. It effectively delayed the defects formation and suppressed interfacial debonding, thereby endowing the contact with excellent impact resistance. Our work presents a fascinated route for designing novel biomimetic Ag-based contacts.

Peeling off behavior of centimeter-level molten pool subjected to subsonic tangential airflow during laser ablation process

In this paper, a computational fluid dynamics model considering the interaction between subsonic tangential airflow and centimeter-level molten pool was established to investigate the melt peeling off behavior during laser ablation process. The results showed that the airflow resulted in violent fluctuations on the surface of molten pool and then flowed upward at a velocity of 2–10.5 m/s, accelerating the surface melt to move upward. A liquid column was formed and elongated slender along the metal surface pushed by the subsonic tangential airflow. An upward-bending tail appeared at the end of the liquid column, which was accelerated up to 6 m/s and then cut off by the airflow, making the melt peel away from the molten pool. Compared with the partial melt peeling off at 0.3 Ma, almost all of the melt was pushed out of the molten pool to peel off when the airflow velocity was increased to 0.5 Ma. When the airflow velocity was further increased to 0.8 Ma, the metal on the surface was accelerated in short time, leading to the peel-off occurring in advance. In addition, the melt temperature decreased due to the forced convection cooling effect of airflow. When the melt solidified, the solid-liquid interfacial tension generated in the liquid column provided tangential force conducive to cutting off the liquid column and peeling off. The decrease rate of the melt temperature with time accelerated significantly and then expedited the melt solidifying and peeling off when the airflow velocity was increased to 0.5 Ma. The decrease rate further accelerated and the temperature decrease occurred earlier at 0.8 Ma, reaching a stable state in a shorter time.

Stable production of dissimilar steel joints in construction machinery by narrow gap oscillating laser welding

Narrow gap oscillating laser welding with filler wire is a promising technique for joining high-strength steels in construction machinery. In order to investigate the influence of beam oscillation on the surface morphology and microstructure of weld joints of two types of commonly-used high-strength steels, a comparative study between oscillation welding and non-oscillation welding was conducted. High-speed photography technique was employed to reveal the microstructure and mechanical properties of the dissimilar joints. The results showed that laser beam oscillation produces two effects: one was to enlarge the heated surface of molten pool, while the other was to stir the liquid metal in molten pool periodically. Under the first effect, the fusion between sidewall and weld bead layers was promoted, while under the latter, coarse columnar grains ceased to appear, but finer grains were formed. The weld joints between Q355 and 35 steels exhibited excellent tensile impact bending performance, which was attributed to the grain refinement effect. The results also demonstrated that the oscillation welding with a contact angle less than 50° could avoid lack of fusion in multi-pass wire-filling laser welding. The influence of the oscillation welding process on the quality of welding was further discussed.

Influence of oscillation parameters on energy distributions and dynamic behaviors during laser welding of aluminum alloy T-joints assisted with solder patch

The laser energy distribution on base material (BM) surface plays an important role in the welding quality. To reduce pore and spatter welding defects during laser welding of aluminum alloy T-joints, a circular shaped oscillating laser beam welding (OLBW) method for aluminum alloy T-joints assisted with solder patch is proposed in this paper. An energy distribution model and a dynamic model for OLBW of aluminum alloy T-joints assisted with solder patch are established to analyze the influence of oscillation parameters on energy distributions of BM surface and dynamic behaviors of molten pool and keyhole. The energy distribution characteristics are obtained by the energy distribution model and the dynamic behaviors of molten pool and keyhole are calculated by the dynamic model for OLBW of aluminum alloy T-joints assisted with solder patch. The results show that the uniformity of energy distribution is improved with the increase in oscillation amplitude or frequency. The oscillation parameters can be adopted to adjust the keyhole stability and the temperature distributions, flow velocities and morphologies of molten pool, which is of great importance for aluminum alloy T-joints welding with high quality.

Novel flat-top laser-aided cold metal transfer additive manufacturing for titanium alloy: Arc characteristics, microstructure, and tensile properties

In this paper, a novel flat-top laser-aided cold metal transfer additive manufacturing (F-LCAM) method is proposed for titanium alloys to restrict internal defects and anisotropy of mechanical properties in large-scale additive-manufactured titanium structures. The proposed method uses a flat-top laser to stabilise the drifting cathode spot and suppress the irregular shape of the weld deposit by promoting thermionic emission on the molten pool surface. Compared to the cold metal transfer additive manufacturing (CMT-AM) process, the auxiliary flat-top laser promotes the wettability of the molten pool and increases the contact angle of deposition from 95° to 142° in an F-LCAM sample. The non-destructive X-ray testing (NDT) results of multi-bead multilayer deposition showed that the defects caused by the pool weld bead morphology were effectively suppressed. Attributed to fluid flow in the melt pool enhanced by the flat-top laser, the dendritic arms were broken, columnar β grains in the F-LCAM sample were finer than in CMT-AM sample, and the aspect ratios of prior-β grains decreased from approximately 6 to 1. The F-LCAM sample exhibited a higher elongation and lower anisotropy than the CMT-AM sample. Defects were observed on the fracture surfaces of the CMT-AM vertical samples, which reduced the elongation of the CMT-AM samples to lower than that of the F-LCAM sample. The ultimate tensile strength, yield strength, and elongation of the multi-bead multilayer deposition met the standards of as-forged Ti6321 titanium alloy, indicating that the Ti6321 titanium alloy structure fabricated by the F-LCAM process has acceptable tensile properties for engineering applications.

Multi-Physics Modeling of Melting-Solidification Characteristics in Laser Powder Bed Fusion Process of 316L Stainless Steel.

In the laser powder bed fusion process, the melting-solidification characteristics of 316L stainless steel have a great effect on the workpiece quality. In this paper, a multi-physics model was constructed using the finite volume method (FVM) to simulate the melting-solidification process of a 316L powder bed via laser powder bed fusion. In this physical model, the phase change process, the influence of temperature gradient on surface tension of molten pool, and the influence of recoil pressure caused by the metal vapor on molten pool surface were considered. Using this model, the effects of laser scanning speed, hatch space, and laser power on temperature distribution, keyhole depth, and workpiece quality were studied. This study can be used to guide the optimization of process parameters, which is beneficial to the improvement of workpiece quality.

Modeling of heat transfer in target material during the electron beam evaporation process

Numerical simulation provides a new method to study the heat and mass transfer behavior during the electron beam evaporation (EBE) process, which can obtain some physical quantities that cannot be accurately measured in experiments. In this study, a mathematical model is established to investigate the evaporation behavior, the variation of temperature field and flow field of target material during the EBE process, and verified through experiments. The results show that the evaporation rate of target material is extremely non-uniform on the molten pool surface, which the calculation error of the evaporation rate was 2.78 %. The solid-liquid interface obtained by numerical simulation is basically consistent with the experiment, which the calculation error of the molten pool depth was 3.57 % and the calculation error of the molten pool width was 1.18 %. In addition, the surface temperature and flow rate of the molten pool increased with the increase of the electron beam power, the depth and the width of the molten pool increased linearly with the increase of the electron beam power and then level off. The model can accurately describe the variations of temperature field and flow field during the EBE process, and then make reliable predictions based on the simulation results.

Motion Behavior of Ce‐Containing Inclusions in 8Cr4Mo4V‐Bearing Steel during Vacuum Arc Remelting

Herein, the Ce‐containing inclusions in8Cr4Mo4V‐bearing steel are taken as the research objective to develop anumerical model of inclusions motions behavior. The model is validated bycomparing it with experimental data. During the vacuum arc remelting process, inclusions move along the molten pool's surface toward the edge under theaction of resultant force, and finally become trapped within the mushy zone. Notably, the majority of inclusions are concentrated near the ingot's edge, andtheir numbers decrease as the radial distance decreases. Furthermore, thenumber of Ce‐Mg‐O‐S inclusions exceeds that of Ce‐O‐S inclusions near the ingot's center. This discrepancy arises due to lower density of Ce‐Mg‐O‐Sinclusions, which exhibits a stronger tendency to migrate toward the moltenpool's center. Additionally, as the inclusion diameter increases, buoyancy forceacting on the inclusions increases, resulting in a higher number of inclusionsnear the ingot's center. When considering the effect of gas cooling, theinclusion distribution becomes more pronounced at the ingot's edge. This isattributed to the enhanced cooling capacity of the mold resulting in the decreasing of molten pool depth and consequently a stronger ability of themushy zone to trap inclusions.

Investigation of thermal behavior of powder stream and molten pool during laser-based directed energy deposition

Laser-powder interaction and molten pool evolution are two main physical processes in laser-based directed energy deposition (L-DED), which greatly affect the morphology and quality of the deposition layer. In this research, a comprehensive three-dimensional analytical-numerical model which integrates a laser-powder interaction model and material deposition model is developed to study the multi-physics coupling characteristics in L-DED process. The concentration of the powder stream is modeled based on conservation of mass and is in good agreement with the experimental result which is captured by high-speed camera. The effects of main parameters, including laser power, powder feeding rate, powder feeding angle and defocus length on the laser attenuation and the temperature distribution of the in-flight powder particles are analyzed. The results show that the laser attenuation rate increases from 0.72% to 1.36% with the powder feeding angle increasing from 45 deg. to 65 deg-. However, the laser attenuation rate is almost the same with the defocus length of 25 mm, 35 mm and 45 mm. Moreover, the peak powder temperature on the deposition surface increases with the increase of powder feeding angle and decrease of defocus length. Accordingly, the heat and mass input conditions at the molten pool surface for the material deposition model, including powder mass flux, effective laser intensity and powder temperature are obtained from the laser-powder interaction model. The heat transport and fluid dynamics of the molten pool are discussed based on the calculated results from material deposition model. Finally, the calculated molten pool geometry shows good agreement with the experimental results with the relative error <8.5%. This work is helpful in process optimization from the point of view of adjusting the parameters related to the powder stream and deeper understanding of laser-powder interaction and molten pool evolution during the L-DED process.

Molten pool free surface solidification behavior in laser remelted near-β titanium alloy

Free surface solidification (FSS) is a common physical phenomenon that has been found by various studies in metallurgy field while targeted studies are rare. This work investigated special structure and formation mechanism of surface grains generated by free surface solidification through laser remelting a near-β titanium alloy Ti-5Al-5Mo-5V-1Cr-1Fe (Ti-55,511). A thin layer crystal film covers molten pool surface through two-dimensional constrained solidification, which can be classified into flake-like crystal film located at molten pool edge and lotusleaf-like crystal film at molten pool center. Numerous cells grow from overflowing melt chill zone around molten pool edge and undergo two-dimensional constrained growth on surface, forming flake-like crystal films. TiNx particles formed from surface melt and N2 reaction can act as heterogeneous crystal nuclei, forming lotusleaf-like crystal films, whose secondary dendrite arm growth direction transforms from 〈100〉 of primary dendrite arm to 〈110〉. Equiaxed lotusleaf-like crystal films and columnar flake-like crystal films have a competitive growth relationship. Inward growth cells growing from two kinds crystal films form flake-like surface grains and central surface grains, respectively. This study can provide FSS theoretical guidance for laser additive manufacturing and surface modification.

Effect of nano-ZrO2 protective layer on the microstructure and surface property strengthening mechanism of underwater wet laser Fe-based cladding layer

Underwater wet laser cladding technology has become one of the research hotspots in the marine engineering, but the existence of the water environment inevitably leads to process instability and defects. In this study, the nano-ZrO2 protective layer was used to increase the viscosity of the molten pool surface to resist the impact force generated by the high-speed water jet, and the underwater wet laser Fe-based cladding layer with good forming quality and desirable performance was successfully prepared. The nano-ZrO2 protective layer improved the formability of the cladding layer and guaranteed the depth of the melt pool, while reducing the depth of the heat affected zone. The addition of nano-ZrO2 particles reduced the average grain size of the cladding layer from 4.90 μm to 3.66 μm. In addition,the corrosion resistance of the cladding layer was greatly improved with the application of the nano-ZrO2 protective layer, with the evident passivation region of 0.74 V. The wear rate of the cladding layer with the nano-ZrO2 protective layer (0.64×10-15m3N-1m-1) was significantly lower than that of the substrate (9.01×10-15m3N-1m-1), and the excellent wear resistance of the cladding layer with nano-ZrO2 protective layer benefited from the good carrying capacities and high microhardness of the microstructure with ZrO2 particles. This study reveals the strengthening mechanism of nano-ZrO2 protective layer on the Fe-based cladding layer, which can provide theoretical guidance for the development of the underwater laser cladding.

Numerical analysis of the behavior of molten pool and the suppression mechanism of undercut defect in TIG-MIG hybrid welding

In order to investigate the multi-coupling transport phenomena in TIG-MIG hybrid arc welding, a three-dimensional model including droplet and molten pool was established. An innovative distribution pattern of arc heat and force that adapted to the evolution of molten pool surface was proposed, achieving a unified distribution of "arc current density-arc pressure-electromagnetic force-arc heat". The effect of TIG arc on molten pool behavior and undercut defect was quantitatively analyzed by comparing TIG-MIG hybrid welding with traditional MIG welding. The results showed that the electromagnetic repulsion between the two arcs with opposite currents increased the aspect ratio of the hybrid arc heat and force distribution. It led to a long and narrow gouging region, where the promoting effect of inertial force on the undercut was weakened by arc pressure and hydrostatic pressure. The liquid metal with a lower cooling rate had sufficient time to fully fill the weld toe and suppressed undercut. Sensitivity and dimensional analysis illustrated that the TIG-MIG hybrid arc eliminated undercut by reducing the inertia force, adjusting the arc pressure distribution, and enhancing the hydrostatic pressure. The groove sizes was predicated based on molten pool characteristics, including the stress state of liquid metal, morphology, and fluid flow patterns. It revealed the quantitative relationships among welding parameters, behavior of molten pool, and weld bead formation, promoting the implementation of digital twinning technology in the manufacturing industries.

A high-fidelity comprehensive framework for the additive manufacturing printability assessment

Additive manufacturing is capable of fabricating complex and customized components that cannot be easily and economically produced by other techniques. It is of great significance to determine the printability map for the extensive application of the fabricated parts, which has been hindered by the common defects such as interior pores and surface roughness. Here, a comprehensive framework including multiphysics model, physics-informed machine learning, and experimental data is proposed to predict the printability. The characteristics for different phenomena (lack of fusion, balling and keyhole) are analyzed by the mechanistic model considering high-fidelity powder-scale model, fluid flow, recoil pressure and Marangoni effect, which provides a more accurate thermal history, molten pool dynamics and surface morphology compared to the finite element model. Classification criterion is established by three mechanistic variables based on the molten pool morphology, which divides the process map into four regions. For the first time, the relationship between the solidified-track surface morphology and the interior quality is established, and the optimal surface morphology corresponding to defect-free printing is determined. The printability is predicted by mathematical machine learning classification models via 10-fold cross-validation method, which validates the classification criterion and the comprehensive framework to assess the printability. This high-fidelity comprehensive framework to assess the printability could potentially guide the alloy design and printing parameters selection towards mass additive manufacturing production.

Effects of Flowrate of Additional Shielding Gas on the Properties of Welded Seam Using Twin-Wire GMAW Welding for Duplex Stainless Steel

Aiming to diminish the defects caused by high-speed pulsed GMAW (Gas Metal Arc Welding), such as lack of penetration, lack of fusion, humping and undercut, this paper proposes an improved twin-wire GMAW welding process by introducing the impact of additional shielding gas on the molten pool, and the effects of different shielding gas flowrates on the mechanical properties and microstructure of the welded seams were investigated. The purpose of introducing additional shielding gas was to use the airflow hood formed by gas injection to isolate air. The impact force generated by the jet might change the original natural solidification mode of the molten pool, which had the effect of improving weld formation and stirring the pool. The airflow hood formed during the process of the additional shielding gas jet impact welding of the molten pool might extend the protection time for the surface of the welding molten pool. The 2205 duplex stainless steel plate was used as the base material for the butt welding test, and the welded seams were subjected to a tensile test, hardness analysis, and metallographic analysis. The results indicated that as the flowrate of additional shielding gas increased in the range of 8 L/min~16 L/min, the width of the welded seam increased and the height of reinforcement decreased gradually. However, a weld seam with a lower middle region and higher sides would appear when the gas flowrate became excessively large. Under the identical welding current and for welding speeds of 160 cm/min, 180 cm/min and 200 cm/min, respectively, the joint formed under the flowrate of 12 L/min had the highest tensile strength (824.3 MPa) among the test specimens under different flowrates of 8 L/min, 12 L/min and 16 L/min. The test results indicated that the jet impact force was relatively moderate when the flowrate of the additional shielding gas was 12 L/min, and thus was optimal for the welded seam.

Multi-phase flow simulation of powder streaming in laser-based directed energy deposition

As a promising additive manufacturing technique, laser-based directed energy deposition has been widely applied in part fabrication, surface cladding, and part restoration. During the powder feeding process, the gas, particles, and laser interact and further affect the molten pool flow. To study the powder feeding process, a multi-physics gas-particle multi-phase flow model coupled with a laser ray-tracing heat source model is developed to predict the powder particle temperature, velocity, and concentration distribution as well as laser energy loss, which is then validated against experimental results. The single-nozzle simulation shows that powder particles out of the nozzle follow a radial Weibull distribution instead of a 2D Gaussian distribution from the inlet of the nozzle. In the four-nozzle powder feeding process, the particles converge further after passing the focal plane, and setting the focal plane above the molten pool surface could potentially increase the powder catchment. Moreover, the laser ray-tracing model incorporates laser reflection and laser incident angle into laser energy loss calculation, which would be more accurate than those models based on the Beer-Lambert law. Additionally, by increasing the powder feed rate or decreasing the carrier gas flow rate, the laser energy loss linearly increases. The predicted powder velocity, temperature distribution, and attenuated laser can be further implemented into the molten pool flow model to more comprehensively study the interaction between particles and the molten pool in the future.