A thermal finite element model with efficient computation of surface heat fluxes for directed-energy deposition process and application to laser metal deposition of IN718

In this study, a numerically efficient thermal finite element process model is developed to predict the melt-pool characteristics of directed-energy deposition (DED) process. The uses new technique compute effective surface heat loss terms in form volumetric sink term order avoid redefinition fluxes from free-surfaces after addition every layer. addition, incorporated losses due evaporation and Marangoni effect by changing conductivity at liquid state. melt pool dimensions IN718 were experimentally measured in-situ monitoring ex-situ optical microscopy cross-sections deposited tracks. proposed accurately predicts experimental single-track multi-layer depositions over range parameters.