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<p>This paper presents a simulation framework to predict deformation induced by residual stress during the laser direct energy deposition (LDED) process. The thermal and structural analysis models were constructed separately. A thermal analysis model was created to calculate the amount of heat input used in the material in the LDED process and identify the thermal boundary conditions for the structural model. In the structural analysis model, the temperature boundary condition was designed based on the change in temperature distribution calculated in the thermal analysis model. To model plastic deformation, a temperature gradient mechanism (TGM)-based inherent strain formulation was applied. The simulation results were validated by comparing numerical predictions with temperature and distortion measurements from experiments using AISI M2 powder deposited on an AISI 1008 substrate. The model showed less than 10% error in major deformation directions and demonstrated strong predictive capability. This framework provides an efficient and physically interpretable solution for LDED process simulation. It successfully captured in situ thermal stress evolution and demonstrated its potential for practical applications in residual stress control and process optimization.</p>

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Layer-by-layer thermal and plastic deformation modeling of AISI 1008/AISI M2 for detailed analysis of thermo-mechanical interactions in the LDED process

  • 期刊论文

  • 发表日期：

    2025年9月12日

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  • Kyeongsik Ha,
  • Sang Woo Song,
  • Jun-Young Jeon,
  • Wookjin Lee

摘要

This paper presents a simulation framework to predict deformation induced by residual stress during the laser direct energy deposition (LDED) process. The thermal and structural analysis models were constructed separately. A thermal analysis model was created to calculate the amount of heat input used in the material in the LDED process and identify the thermal boundary conditions for the structural model. In the structural analysis model, the temperature boundary condition was designed based on the change in temperature distribution calculated in the thermal analysis model. To model plastic deformation, a temperature gradient mechanism (TGM)-based inherent strain formulation was applied. The simulation results were validated by comparing numerical predictions with temperature and distortion measurements from experiments using AISI M2 powder deposited on an AISI 1008 substrate. The model showed less than 10% error in major deformation directions and demonstrated strong predictive capability. This framework provides an efficient and physically interpretable solution for LDED process simulation. It successfully captured in situ thermal stress evolution and demonstrated its potential for practical applications in residual stress control and process optimization.