A coupled multiphase Lagrangian-Eulerian fluid-dynamics framework for numerical simulation of Laser Metal Deposition process

Abstract We present a Computational Fluid Dynamics (CFD) framework for the numerical simulation of Laser Metal Deposition (LMD) process in 3D printing. Such framework, comprehensive both formulations and solvers, aims at providing sufficiently exhaustive scenario process, where carrier gas, modeled as an Eulerian incompressible fluid, transports metal powders, tracked Lagrangian discrete particles, within printing chamber. On basis heat sources coming from laser beam heated substrate, particle model is developed to interact with gas also by transfer evolve melted phase according growth law liquid mass fraction. Enhanced characterized modified Newton-Raphson scheme parallel algorithm tracking are employed obtain efficiency accuracy strategy. In perspective investigating optimal design whole LMD we propose sensitivity analysis specifically addressed assess influence inflow rates, beams intensity, nozzle channel geometry. campaign performed in-house code open source Finite Element library, publicly available online.