Analysing the Influence of Geometry and Tool Paths for a Laser-Based DED Application

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Abstract
This study examines the coupled effects of geometry type and toolpath patterns on residual stresses and strains in parts manufactured using laser-based Directed Energy Deposition (DED). Finite Element Method (FEM) simulations were conducted for four distinct geometries, each subjected to three different tool-path strategies: one-way longitudinal, longitudinal zigzag, and one-way transverse. The plastic strain is highly correlated with the maximum temperature within the deposition. The longer walls also gain higher strains in the deposition direction. The highest tensile strains were observed in the upper layers of the structures, while the mid-layers exhibited the maximum principal residual stresses. Additionally, thin walls are more sensitive to deposition patterns than thick walls due to limited heat dissipation. These insights provide a foundation for optimizing toolpath strategies in laser-based DED processes, aiming at improved mechanical performance and reduced distortion in complex geometries.