2D linear finite element simulation of laser metal heating for digital twins

Abstract

In the context of laser-based additive manufacturing, the thermal behavior of the substrate is relevant to define process parameters vis-à-vis piece quality. The existing literature focuses on two process variables: (a) lumped laser power and (b) process speed. However, this literature does not consider other variables, such as those related to the laser power distribution. To fill this vacuum, this manuscript includes the laser power spatial distributions (Gaussian, uniform circular and uniform rectangular) in addition to (a) and (b) above in 2D linear substrate heating simulations. The laser energy is modeled as a time dependent heat flux boundary condition on top of the domain. The total laser delivered power was identical for all spatial distributions. The results show that the laser intensity spatial distribution strongly affects the maximum temperature, and the depth and width of the heat affected zone. These 2D finite element simulations prove to be good options for digital twin based design environments, due to their simplicity and reasonable temperature error, compared to non-linear analysis (considered as ground truth for this case). Future publications address non-linear finite element simulations of the laser heating process (including convection and radiation and temperature dependent substrate properties).