A grey-box model of laser-powder directed energy deposition for complex scanning strategy

Directed Energy Deposition using a laser based system (DED-LB) is a technology that enables the repair of components, cutting costs and saving resources when it comes to valuable and expensive components. Furthermore, this method can be used in the production of multi-material components. Despite its benefits, DED-LB process has limitations as well, particularly in terms of resolution, surface quality, and dimensional accuracy. Optimisation of scanning parameters and strategies, as well as the use of new materials, appears to be advantageous in this regard. Simultaneously, the use of methods such as numerical simulation expedites the process of becoming familiar with the technology, thereby improving optimization tasks. DED-LB process starts with one track; the research and optimisation of its properties are crucial, as they affect the outcome of the DED-LB component. In this research article, a novel grey-box model that exhibits the ability to precisely predict the temperature distribution and track dimensions was introduced. The proposed model adopts a numerical–analytical methodology, yielding outcomes at a comparatively reduced computational expense while upholding precision in the obtained results. The proposed modelling approach is based on the solution of the heat equation coupled with an iterative feedback loop to quantify the power losses and ensure energy and mass balance at the melt pool. The model is used to forecast the temperature field and track characteristics for a collection of linear tracks while varying the main process parameters in order to study their effect on track characteristics. In addition, this model can be used to predict the course of more complex trajectories; to illustrate this, an application in which both circular and square tracks are made was presented.