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Investigation of Heat-Mass Transfer and Residual Stress of Laser-Directed Energy Deposition Under Multiple Cladding Categories.

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Title: Investigation of Heat-Mass Transfer and Residual Stress of Laser-Directed Energy Deposition Under Multiple Cladding Categories.
Authors: Liu, Yanming1,2 (AUTHOR), Liu, Weiwei1,2,3 (AUTHOR) liuww@dlut.edu.cn, Ouyang, Jinhua1,2 (AUTHOR), Ma, Yali1,2 (AUTHOR), Wang, Fengtao4 (AUTHOR), Zhang, Hongchao1,2 (AUTHOR)
Source: JOM: The Journal of The Minerals, Metals & Materials Society (TMS). Jun2026, Vol. 78 Issue 6, p5562-5578. 17p.
Subjects: Residual stresses, Metal cladding, Laser deposition, Liquid metals, Process optimization, Computational fluid dynamics, Heat transfer
Abstract: Standard laser-directed energy deposition (DED-L) processes based on horizontal substrates and vertically incident laser beams are often inadequate for accommodating complex and variable engineering scenarios. In this study, a computational fluid dynamic (CFD) model based on the volume-of-fluid (VOF) approach was developed to simulate DED-L on inclined substrates, incorporating recoil pressure and Mie scattering effects. A combined experimental and numerical methodology was employed to analyze the formation of melt pool geometry and the associated thermal-mass transport behaviors under varying energy input and gravitational influences across distinct deposition strategies. The results indicate that higher laser power significantly improves powder utilization, leading to increased melt volume and enlarged cross-sectional dimensions. Within a substrate inclination range of 0–45°, greater inclination angles induce downward molten metal flow, thereby reducing melt pool height, depth, and cross-sectional area while increasing width and positional offset. Moreover, increased substrate tilt markedly elevates residual stress within the deposited layer. Comparative assessments of various cladding strategies demonstrate that optimizing deposition orientation effectively reduces residual stress accumulation. These findings offer critical insights into the influence of substrate inclination on DED-L and lay a foundation for process parameter optimization aimed at enhancing cladding quality and structural performance. [ABSTRACT FROM AUTHOR]
Copyright of JOM: The Journal of The Minerals, Metals & Materials Society (TMS) is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 193654196
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Investigation of Heat-Mass Transfer and Residual Stress of Laser-Directed Energy Deposition Under Multiple Cladding Categories.
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  Data: <searchLink fieldCode="DE" term="%22Residual+stresses%22">Residual stresses</searchLink><br /><searchLink fieldCode="DE" term="%22Metal+cladding%22">Metal cladding</searchLink><br /><searchLink fieldCode="DE" term="%22Laser+deposition%22">Laser deposition</searchLink><br /><searchLink fieldCode="DE" term="%22Liquid+metals%22">Liquid metals</searchLink><br /><searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Computational+fluid+dynamics%22">Computational fluid dynamics</searchLink><br /><searchLink fieldCode="DE" term="%22Heat+transfer%22">Heat transfer</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: Standard laser-directed energy deposition (DED-L) processes based on horizontal substrates and vertically incident laser beams are often inadequate for accommodating complex and variable engineering scenarios. In this study, a computational fluid dynamic (CFD) model based on the volume-of-fluid (VOF) approach was developed to simulate DED-L on inclined substrates, incorporating recoil pressure and Mie scattering effects. A combined experimental and numerical methodology was employed to analyze the formation of melt pool geometry and the associated thermal-mass transport behaviors under varying energy input and gravitational influences across distinct deposition strategies. The results indicate that higher laser power significantly improves powder utilization, leading to increased melt volume and enlarged cross-sectional dimensions. Within a substrate inclination range of 0–45°, greater inclination angles induce downward molten metal flow, thereby reducing melt pool height, depth, and cross-sectional area while increasing width and positional offset. Moreover, increased substrate tilt markedly elevates residual stress within the deposited layer. Comparative assessments of various cladding strategies demonstrate that optimizing deposition orientation effectively reduces residual stress accumulation. These findings offer critical insights into the influence of substrate inclination on DED-L and lay a foundation for process parameter optimization aimed at enhancing cladding quality and structural performance. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of JOM: The Journal of The Minerals, Metals & Materials Society (TMS) is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1007/s11837-026-08296-4
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      – Code: eng
        Text: English
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        PageCount: 17
        StartPage: 5562
    Subjects:
      – SubjectFull: Residual stresses
        Type: general
      – SubjectFull: Metal cladding
        Type: general
      – SubjectFull: Laser deposition
        Type: general
      – SubjectFull: Liquid metals
        Type: general
      – SubjectFull: Process optimization
        Type: general
      – SubjectFull: Computational fluid dynamics
        Type: general
      – SubjectFull: Heat transfer
        Type: general
    Titles:
      – TitleFull: Investigation of Heat-Mass Transfer and Residual Stress of Laser-Directed Energy Deposition Under Multiple Cladding Categories.
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      – PersonEntity:
          Name:
            NameFull: Liu, Yanming
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          Name:
            NameFull: Liu, Weiwei
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            NameFull: Ouyang, Jinhua
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            NameFull: Ma, Yali
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            NameFull: Wang, Fengtao
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            NameFull: Zhang, Hongchao
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            – D: 01
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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              Value: 78
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              Value: 6
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            – TitleFull: JOM: The Journal of The Minerals, Metals & Materials Society (TMS)
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