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HomeKey Engineering MaterialsKey Engineering Materials Vol. 1047Comparison between 2D and 3D Thermal Finite...

Comparison between 2D and 3D Thermal Finite Element Models of Directed Energy Deposition

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Abstract:

Varying boundary conditions, such as convection, radiation, and contact thermal exchange parameters in Directed Energy Deposition (DED) process modeling, can significantly impact the predicted thermal fields [1] and final properties of a product. The current numerical study analyzes the effect of different boundary conditions on the temperature distribution during DED thanks to a 3D model of AISI M4 tool steel validated by an experimental campaign. It also confirms that a 2D FE model can already provide valuable trends about sensitivity of numerical results to boundary conditions. The accuracy and robustness of the 2D and 3D model predictions are analyzed. The temperature histories of a set of points at different heights in the clad and the melt pool dimensions provide experimental validation.

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Additive Manufacturing

Info:

Periodical:

Key Engineering Materials (Volume 1047)

Pages:

359-371

Online since:

April 2026

Authors:

Calogero Gallo*, Samuel Van Hulle, Jérôme Tchoufang Tchuindjang, Anne Mertens, Laurent Duchene, Anne Marie Habraken

Keywords:

Additive Manufacturing, DED, FE Model, M4 Steel, Sensitivity Analysis

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Creative Commons CC BY 4.0

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* - Corresponding Author

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