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<p>This study systematically investigates the thermomechanical response of T-shaped TC4 titanium alloy components fabricated by coaxial wire–powder multi-laser melting deposition (CWP-Multi-LMD), aiming to optimize energy-input parameters to improve dimensional stability and structural integrity. A fully coupled three-dimensional finite element framework was developed to simulate transient temperature fields, residual stress evolution, and deformation behavior under varying combinations of laser power and scanning speed. The results demonstrate that laser power exerts a substantially stronger influence on thermal accumulation and stress generation than scanning speed. Among the four energy–density conditions examined, the lowest input level (E1 = 2.5&#xa0;J<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\cdot\)</EquationSource> <EquationSource Format="MATHML"><math> <mo>·</mo> </math></EquationSource> </InlineEquation>mm<sup>−3</sup>) yielded the most favorable performance, characterized by a reduced peak temperature (312.8&#xa0;°C), a lower temperature gradient (888.1&#xa0;°C·mm<sup>−1</sup>), minimal equivalent residual stress (1.72 × 10<sup>9</sup>&#xa0;Pa), and the smallest distortion (0.107&#xa0;mm). These findings highlight the pivotal role of precise energy–density control in suppressing adverse thermal effects and minimizing mechanical deformation. The outcomes offer robust theoretical guidance for parameter optimization in multi-source laser additive manufacturing of titanium alloys, particularly for high-precision applications in aerospace and biomedical engineering.</p>

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Numerical simulation study of thermal coupling of TC4 components formed by CWP-Multi-LMD with different laser energy densities

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Ziyi Li,
  • Jiuxiao Li,
  • Minhao Fan,
  • Zhiwei Zhao,
  • Chonggui Li

摘要

This study systematically investigates the thermomechanical response of T-shaped TC4 titanium alloy components fabricated by coaxial wire–powder multi-laser melting deposition (CWP-Multi-LMD), aiming to optimize energy-input parameters to improve dimensional stability and structural integrity. A fully coupled three-dimensional finite element framework was developed to simulate transient temperature fields, residual stress evolution, and deformation behavior under varying combinations of laser power and scanning speed. The results demonstrate that laser power exerts a substantially stronger influence on thermal accumulation and stress generation than scanning speed. Among the four energy–density conditions examined, the lowest input level (E1 = 2.5 J \(\cdot\) · mm−3) yielded the most favorable performance, characterized by a reduced peak temperature (312.8 °C), a lower temperature gradient (888.1 °C·mm−1), minimal equivalent residual stress (1.72 × 109 Pa), and the smallest distortion (0.107 mm). These findings highlight the pivotal role of precise energy–density control in suppressing adverse thermal effects and minimizing mechanical deformation. The outcomes offer robust theoretical guidance for parameter optimization in multi-source laser additive manufacturing of titanium alloys, particularly for high-precision applications in aerospace and biomedical engineering.