Comparison of Two-Dimensional and Three-Dimensional Thermal Models of the LENS® Process

Abstract

A new two-dimensional (2D) transient finite element model was developed to study the thermal behavior during the multilayer deposition by the laser engineered net shaping rapid fabrication process. The reliability of the 2D model was evaluated by comparing the results obtained from the 2D model with those computed by a previously developed three-dimensional (3D) model. It is found that the predicted temperature distributions and the cooling rates in the molten pool and its surrounding area agree well with the experiment data available in literature and with the previous results calculated with the 3D model. It is also concluded that, for the geometry analyzed in this study, the 2D model can be used with good accuracy, instead of the computationally much more expensive 3D model, if certain precautions are taken to compensate for the 3D effects of the substrate. In particular, a 2D model could be applied to an in situ calculation of the thermal behavior of the deposited part during the fabrication, allowing dynamic control of the process. The 2D model is also applied to study the effects of substrate size and idle time on the thermal field and size of the molten pool.