Optimization of the LENS® process for steady molten pool size

A three-dimensional finite element model was developed and applied to analyze the temperature and phase evolution in deposited stainless steel 410 (SS410) during the Laser Engineered Net Shaping (LENS®,1) rapid fabrication process. The effect of solid phase transformations is taken into account by using temperature and phase dependent material properties and the continuous cooling transformation (CCT) diagram. The laser beam is modeled as a Gaussian distribution of heat flux from a moving heat source with conical shape. The laser power and translational speed during deposition of a single-wall plate are optimized in order to maintain a steady molten pool size. It is found that, after an initial transient due to the cold substrate, the dependency of laser power with layer number is approximately linear for all travel speeds analyzed. The temperature distribution and cooling rate surrounding the molten pool are predicted and compared with experiments. Based upon the predicted thermal cycles and cooling rate, the phase transformations and their effects on the hardness of the part are discussed.