Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys
Open accessAbstract
Nickel-based super alloys are popular for applications in the energy and aerospace industries due to their excellent corrosion and high-temperature resistance. Direct metal deposition (DMD) of nickel alloys has reached technology readiness for several applications, especially for the repair of turbomachinery components. However, issues related to part quality and defect formation during the DMD process still persist. Laser remelting can effectively prevent and repair defects during metal additive manufacturing (AM); however, very few studies have focused on numerical modeling and experimental process parameter optimization in this context. Therefore, the aim of this study is to investigate the effect of determining the remelting process parameters via numerical simulation and experimental analyses in order to optimize an industrial process chain for part repair by DMD. A heat conduction model analyzed 360 different process conditions, and the predicted melt geometry was compared with observations from a fluid flow model and experimental single tracks for selected reference conditions. Subsequently, the remelting process was applied to a demonstrator repair case. The results show that the models can well predict the melt pool shape and that the optimized remelting process increases the bonding quality between base and DMD materials. Therefore, DMD part fabrication and repair processes can benefit from the remelting step developed here.
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Alumina (Al2O3) can mitigate the effects of erosion and high-temperature corrosion, or remanufacturing processes and coatings with nickel alloys can enhance corrosion resistance.
“Materials like alumina (Al 2 O 3 ) can mitigate the effects of erosion and high-temperature corrosion, or remanufacturing processes and coatings with nickel alloys can enhance corrosion resistance [139,140].”
From Towards Sustainability in Hydraulic Machinery Manufacturing by 3D Printing (2024) · cites this paper as [140]
The Abstract (page not provided) says nickel-based superalloys have excellent corrosion resistance and that direct metal deposition of nickel alloys is used to repair components. It does not say that remanufacturing or nickel-alloy coatings enhance corrosion resistance. The alumina clause may pertain to the other citation in the sentence; this paper does not address it. (LLM, conf=0.84)
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- Authors
- Soffel, F., Lin, Y., Keller, D., Egorov, S., & Wegener, K.
- Affiliations
- Inspire (CH)
- ETH Zurich (CH)
- Corresponding author
- Soffel, Fabian
- Venue
- Materials
- Publisher
- MDPI AG
- Published
- 2021-12-27
- Volume
- 15
- Issue
- 1
- Pages
- 177
- ISSN
- 1996-1944 (ISSN-L)
- PMC
- PMC8746250
- OpenAlex
- W4200044704
- Cited by
- 18
- References
- 26
- Citations by year
- 2026: 1 · 2025: 3 · 2024: 4 · 2023: 6 · 2022: 4
- FWCI
- 1.50
- Type
- journal article
- Language
- en
- Open access
- gold
- doi.org
- Licence
- Locations
- Materials (publishedVersion, cc-by)
- PubMed Central (publishedVersion, cc-by)
- PubMed (publishedVersion)
- DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion, cc-by-sa)
- Repository for Publications and Research Data (ETH Zurich) (submittedVersion, cc-by)
- ETH Zürich Research Collection (cc-by)
- Funders
- Innosuisse - Swiss Innovation Agency (25498)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
- Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
- Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
- Keywords
- laser remelting, direct metal deposition, nickel-based superalloy, process parameter optimization, melt pool geometry, heat conduction model, fluid flow model, defect prevention, bonding quality, process simulation
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