
Themo-mechanical Modelling and Simulation of Laser Metal Deposition with Applications to the Printing of Satellite Launch Interface Rings
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Nowadays, interest on Laser Metal Deposition (LMD) techniques, among other Direct Energy Deposition (DED) schemes, has been in a considerable rise. The main reason for such increase in attention is its ability to deal with the manufacturing of large scale complex components, not to mention its usefulness for repairing high valued parts. In general terms, this LMD technique uses as raw material a metal powder which is blown from nozzles to the deposition area. While in flight, a high power laser beam melts the metal which, after the passing of the laser, solidifies creating in a layer-wise manner the desired component [01]. However, large temperature gradients are induced by such moving heat source, which in turn induce residual stresses and deformations that could impoverish the dimensional accuracy of the manufactured component and in extreme cases cause building failure, cracks and loss of structural integrity. A comprehensive understanding of the physical processes involved in the LMD technique will allow to accurately predict and possibly control such residual stresses and deformations, improving the reliability of the manufacturing process. In general terms, this can be carried out along two parallel and mutually nurturing processes, namely (i) experimental measurement and (ii) numerical simulation. It is the main objective of this communication to convey the endeavours done (i) on the experimental part by the CRM group when producing a breadboard of a satellite Launch Interface Ring (LIR) and (ii) on the other hand by the Cenaero on the simulation of complex multi-physics and multi-scale phenomena by numerical means applied to this AM process [02, 03, 04]. The gained understanding of the particularities of the LMD technique has successfully assisted the LMD-AM process by providing accurate and reliable predictions within affordable computing effort pushing the barriers towards its industrial exploitation.