Thermomechanical modeling of IN718 alloy directed energy deposition process

Directed Energy Deposition (DED) Additive Manufacturing (AM) processes have a great potential to be used as cost-effective and efficient repairing and re-manufacturing processes for aerospace components such as turbine blades and landing gears. The AMOS project intends to connect repair and re-manufacturing strategies with design through accurate DED process simulation and novel multi-disciplinary design optimisation (MDO) methods. The ultimate goal is to reduce aerospace component weaknesses at design stage and prolong their lifecycles. DED AM processes are multi-physical phenomena involving high laser power melting powder or wire on a substrate. An experimental heat source has been calibrated using a heat transfer analysis of IN718 laser and powder AM on a sample part. Residual stresses and final distortion are also computed using thermal field and the evolving part distortion at each increment. Multiple hypotheses have been considered model the molten pool creation on the Heat Affected Zone (HAZ)