Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys.

Area of Science:

• Materials Science
• Manufacturing Engineering
• Additive Manufacturing

Background:

• Nickel-based superalloys offer superior corrosion and high-temperature resistance, crucial for energy and aerospace sectors.
• Direct Metal Deposition (DMD) is viable for repairing turbomachinery but faces challenges with part quality and defects.
• Laser remelting is a promising technique for defect mitigation in additive manufacturing (AM), yet lacks optimized process parameters.

Purpose of the Study:

• To investigate the optimization of laser remelting process parameters for direct metal deposition (DMD) of nickel alloys.
• To enhance the industrial process chain for part repair using numerical simulation and experimental validation.
• To improve the bonding quality between base material and DMD-fabricated components.

Main Methods:

• A heat conduction model simulated 360 process conditions to predict melt geometry.
• Fluid flow modeling and experimental single-track analysis validated simulation predictions.
• Optimized remelting parameters were applied to a demonstrator repair case.

Main Results:

• Numerical models accurately predicted melt pool dimensions.
• Optimized laser remelting significantly improved the bonding quality between the base and DMD materials.
• The developed remelting process is effective for defect repair in DMD components.

Conclusions:

• Numerical simulation combined with experimental analysis provides an effective method for optimizing laser remelting parameters.
• The optimized remelting process enhances the reliability and quality of repaired components via DMD.
• This approach offers significant benefits for both fabrication and repair processes utilizing direct metal deposition.