Wire feeding type directed energy deposition (DED) process is able to produce metal parts with high density at high deposition rate. However, the parts are subjected to high residual stresses and distortion due to its large heat input. In order to simulate the thermal stress, a proper heat input parameter is required. The goal of this paper is to investigate the efficiency and penetration depth of the applied heat flux in the DED process. The estimation method for the penetration depth and efficiency of applied heat flux is proposed using the thermal finite element analyses (FEAs). A finite element model is developed according to the cross sectional profile of the actual deposited beads. A top-hat volumetric heat flux is adopted to simulate the transient thermal phenomenon of the laser based wire feeding type DED process. The estimated heat affected zone (HAZ) from the FEAs is compared with the experimental results in order to estimate the proper efficiency and penetration depth of the laser beam for each condition of DED process.
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