MULTI-PHYSICS MODELING OF LOW-TEMPERATURE DIRECTED ENERGY DEPOSITION OF STAINLESS STEEL 316L

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Date

2023

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University of Texas at Austin

Abstract

The Directed energy deposition (DED) process is greatly influenced by the ambient temperature at on-site repair. In Northern Hemisphere locations, DED is particularly influenced by sub-freezing temperatures. However, its influence on the process is not yet studied. This critical gap is fulfilled in this research through a multi-physics computational fluid dynamics (CFD) modeling of the lowtemperature DED of the SS316L powders. The model is validated with test cases: −3°𝐶 for subfreezing and 20°𝐶 for room temperature cases using a cryogenic DED platform. The modeling involves powder spray, local melting, rapid cooling, solidification, evaporation, and fluid-gas interactions. The results show, at sub-freezing, the molten pool is ~63% bigger with the maximum temperature reduced by ~9.5%. The deposition saw an increase in width by ~8.6% and height by ~26% than the room temperature case. Overall, the versatile modeling-experimental platform helps study cryogenic DED cases for in-space additive manufacturing.

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