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Thermal Behavior and Microstructural Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part I. Numerical Calculations

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Abstract

Laser-engineered net shaping (LENS) is a rapid direct manufacturing process. The LENS process can be analyzed as a sequence of discrete events, given that it is a layer-by-layer process. The thermal history associated with the LENS process involves numerous reheating cycles. In this article, the thermal behavior during laser deposition with LENS is simulated numerically by using the alternate-direction explicit (ADE) finite difference method (FDM). The simulation results showed that deposited material experiences a significant rapid quenching effect during the initial stages of deposition and can attain a very high cooling rate. With an increase in deposit thickness, the rapid quenching effect decreases and eventually disappears. The effects of the processing parameters on the thermal behavior of deposited materials were also simulated and analyzed. The objective of this study is to provide insight into the thermal history during the LENS process, where the ability to correlate process parameters to microstructural evolution is a motivating force.

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Notes

  1. LENS is a trademark of Sandia National Laboratories, and is commercialized by Optomec, Inc., Albuquerque, NM.

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Acknowledgments

This work was supported by the National Science Foundation under Grant No. DMI-0423695 and by NASA Marshall under Contract No. NNM06AB11C. Work at Sandia National Laboratories is supported by the United States Department of Energy under Contract No. DE-AC04-94AL85000.

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Authors and Affiliations

  1. Department of Chemical Engineering and Materials Science, University of California, Davis, CA, 95616, USA

    B. Zheng (Postdoctoral Researcher), Y. Zhou (Associate Researcher), J.M. Schoenung (Professor) & E.J. Lavernia (Dean of College of Engineering)

  2. Sandia National Laboratories, Livermore, CA, 94551-0969, USA

    J.E. Smugeresky (Senior Staff Member)

Authors
  1. B. Zheng
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  2. Y. Zhou
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  3. J.E. Smugeresky
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  4. J.M. Schoenung
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  5. E.J. Lavernia
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Correspondence to B. Zheng.

Additional information

Manuscript submitted October 22, 2007.

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Zheng, B., Zhou, Y., Smugeresky, J. et al. Thermal Behavior and Microstructural Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part I. Numerical Calculations. Metall Mater Trans A 39, 2228–2236 (2008). https://doi.org/10.1007/s11661-008-9557-7

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  • DOI: https://doi.org/10.1007/s11661-008-9557-7

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