Effect of Pre-Heating on Residual Stresses and Deformation in Laser-Based Directed Energy Deposition Repair: A Comparative Analysis

Laser-directed energy deposition (DED), a metal additive manufacturing method, is renowned for its role in repairing parts, particularly when replacement costs are prohibitive. Ensuring that repaired parts avoid residual stresses and deformation is crucial for maintaining functional integrity. This study conducts experimental and numerical analyses on trapezoidal shape repairs, validating both the thermal and mechanical models with experimental results. Additionally, the study presents a methodology for creating a toolpath applicable to both the DED process and Abaqus CAE software. The findings indicate that employing a pre-heating strategy can reduce residual stresses by over 70% compared to no pre-heating. However, pre-heating may not substantially reduce final distortion. Notably, final distortion can be significantly mitigated by pre-heating and subsequently cooling to higher temperatures, thereby reducing the cooling rate. These insights contribute to optimizing DED repair processes for enhanced part functionality and longevity.