Research Article

NUMERICAL INVESTIGATION OF THE EFFECTS OF SCANNING DIRECTION AND LASER POWER DENSITY ON THERMOMECHANICAL BEHAVIOR IN ADDITIVE MANUFACTURING USING THE DED METHOD

Volume: 28 Number: 3 September 3, 2025
EN TR

NUMERICAL INVESTIGATION OF THE EFFECTS OF SCANNING DIRECTION AND LASER POWER DENSITY ON THERMOMECHANICAL BEHAVIOR IN ADDITIVE MANUFACTURING USING THE DED METHOD

Abstract

In this study, the effects of different scanning direction and laser power density conditions on the thermomechanical behavior of metal additive manufacturing via the Directed Energy Deposition (DED) method were investigated through numerical simulations. A three-dimensional thermomechanical analysis model was developed using Simufact Welding software to evaluate the temperature distribution, thermal stresses, and plastic deformation behavior under two scanning directions and laser power densities. The results revealed that both scanning directions and laser parameters significantly influence temperature gradients and the accumulation of residual stress fields. In particular, more homogeneous temperature distributions were achieved at lower laser power levels, which in turn resulted in reduced residual stresses. The findings emphasize that the optimization of scanning direction and energy input parameters is essential to ensure manufacturability and enhance the structural integrity of parts fabricated through the DED process.

Keywords

References

  1. A.V. Gusarov, M. Pavlov, I. Smurov. (2011). Residual stresses at laser surface remelting and additive manufacturing, lasers in manufacturing 2011, in: Proceedings of the Sixth International Wlt Conference on Lasers in Manufacturing, vol 12, Pt A 12(1) 248–254. https://doi.org/10.1016/j.phpro.2011.03.032.
  2. Akbulut, E. (2019). Investigating The Effects of The Scanning Strategy and Layer Thickness for Electron Beam Melting By Using Finite Element Method. M.Sc. Thesis. Istanbul Technical Unıversity.
  3. Alimardani, (2009). Multi-physics analysis of laser solid freeform fabrication, PhD Thesis, University of Waterloo.
  4. Arce, (2012). Thermal modeling and simulation of electron beam melting for rapid prototyping on Ti6Al4V alloys, PhD Thesis, University of Raleigh, North Carolina.
  5. Aşçı, M., İ. (2019). Lazerli Metal Yığma Prosesinin Sonlu Elemanlar Metoduyla Termo-Mekanik Analizi. Kahramanmaraş Sütçü İmam Üniversitesi.
  6. Aşçı, M., İ., Ermurat, M. (2019). Investigation Of Laser Metal Deposition Method by Finite Element Analysis: Laser Speed Effect on Thin Walled Geometry Building. Kahramanmaras Sutcu Imam University Journal of Engineering Sciences.
  7. Bielik M, “Thermo-mechanical analysis of plasma-based additive manufacturing of Ti-6Al-4V components using Simufact Welding 8.0”. Master Thesis. Vienna: Vienna University of Technology, June 2020.
  8. Cao, J. Gharghouri, A., M. Nash, P. (2016). Finite-Element Analysis and Experimental Validation of Thermalresidual Stress and Distortion İn Electron Beam Additive Manufacturedti-6Al-4V Build Plates. Journal of Materials Processing Technology 237 (2016) 409–419.

Details

Primary Language

Turkish

Subjects

Numerical Methods in Mechanical Engineering , Mechanical Engineering (Other) , Additive Manufacturing

Journal Section

Research Article

Publication Date

September 3, 2025

Submission Date

April 14, 2025

Acceptance Date

May 26, 2025

Published in Issue

Year 1970 Volume: 28 Number: 3

APA
Aşçı, M. İ., & Ermurat, M. (2025). DED YÖNTEMİYLE EKLEMELİ İMALATTA TARAMA YÖNÜ VE LAZER GÜÇ YOĞUNLUĞUNUN TERMOMEKANİK DAVRANIŞ ÜZERİNE ETKİLERİNİN SAYISAL İNCELENMESİ. Kahramanmaraş Sütçü İmam Üniversitesi Mühendislik Bilimleri Dergisi, 28(3), 1375-1385. https://doi.org/10.17780/ksujes.1675994