Numerical simulation of thermal behavior during laser metal deposition shaping

Based on the element life and death theory of finite element analysis(FEA), a three-dimensional multi-track and multi-layer model for laser metal deposition shaping(LMDS) was developed with ANSYS parametric design language(APDL), and detailed numerical simulations of temperature and thermal stress were conducted. Among those simulations, long-edge parallel reciprocating scanning method was introduced. The distribution regularities of temperature, temperature gradient, Von Mise's effective stress, X-directional, Y-directional and Z-directional thermal stresses were studied. LMDS experiments were carried out with nickel-based superalloy using the same process parameters as those in simulation. The measured temperatures of molten pool are in accordance with the simulated results. The crack engendering and developing regularities of samples show good agreement with the simulation results.