Product Code: ICAL06_803

Three-dimensional Finite Element Models for the Calculation of Temperature and Residual Stress Fields in Laser Cladding
Authors:
Augusto Deus, Instituto Superior Tecnico; Lisboa Portugal
Jyoti Mazumder, University of Michigan; Ann Arbor MI USA
Presented at ICALEO 2006

Laser Cladding (LC) and Direct Material Deposition (DMD) are well established Rapid Manufacturing techniques, in which a heat source -the laser beam- is brought together with a mass source -usually delivered in the form of a powder- in order to produce a 3D object. 3D transient thermal and mechanical lagrangean FE models, consistent with the additive nature of the process, were developed using the AbaqusTM software package. Distinct features include: a) the clad advancing front is curved in shape, which is verified to be a proper approach in the heat transfer description of LC; b) continuous composition variation across the coating-substrate interface is incorporated, where a simple dilution model is utilized to calculate the local composition evolution, as determined by the thermal cycle. Temperature and residual stress profiles were calculated, for cladding of C95600 copper- on AA333 aluminum-alloy. FE models of LC and DMD are useful: a) to investigate the range of processing parameters that lead to successful deposition, in terms of heat transfer, stress and dilution requirements; b) to generate data that can be translated into tool path commands in CAM; c) to develop strategies for avoiding failure during laser assisted fabrication or later, under service conditions.