A fast physics-based thermal model for wire laser-based directed energy deposition

Metal Additive Manufacturing (AM) processes are increasingly adopted because they combine high part quality with improved cost and time efficiency compared to conventional methods. However, Directed Energy Deposition (DED) processes still require extensive effort during setup to identify process parameters that ensure part quality. Given the complexity of the underlying physical phenomena, physics-based process modeling is essential for efficient process setup and planning. This work presents a fast macro-scale thermal simulation model for the wire laser-based DED (DED-LB) process, which, although less mature, is highly promising. The enthalpy method is employed to model heat diffusion, enabling reliable prediction of the temperature field and melt pool geometrical characteristics within computational times suitable for engineering applications. The results show consistently good performance, validated through correlation with experimental data for two feedstock materials, multiple geometries, and a range of process parameters.