Data: Thermo-Capillary-Gravity Bidirectional Modelling for Evaluation and Design of Wire-Based Directed Energy Deposition Additive Manufacturing

In this study, a thermo-capillary-gravity bidirectional analytical model is developed based on the fundamental governing physics, enabling fast predictions of both w-DED bead geometries and process parameters. A novel method is also proposed to determine the power transfer efficiency and wire melting efficiency defined in the model. In the forward modelling, deposit bead geometries, such as layer height and width, can be predicted for given process parameters and material properties. In the reverse modelling, the outputs of the model are process parameters, including heat source power and travel speed, to achieve the deposit bead geometries as required for a given application. This bidirectional modelling approach is applicable to different w-DED processes, and it has been validated for the deposition of steel walls using plasma transferred arc and cold wire gas metal arc processes. The developed bidirectional analytical model could be used as an efficient and reliable tool for w-DED process evaluation and design.

本研究基于基础控制物理机制，构建了热毛细重力双向解析模型（thermo-capillary-gravity bidirectional analytical model），可快速预测线材定向能量沉积（wire Directed Energy Deposition, w-DED）的熔敷道几何形貌与工艺参数。本研究同时提出了一种新方法，用于确定该模型中定义的功率传递效率与焊丝熔化效率。在正向建模环节，可针对给定的工艺参数与材料属性，预测熔敷道的层高、宽度等几何特征。在反向建模环节，模型输出为工艺参数（包括热源功率与移动速度），以实现特定应用场景下所需的熔敷道几何形貌。该双向建模方法适用于各类线材定向能量沉积工艺，并已通过采用等离子转移弧与冷丝气体金属电弧工艺沉积钢制墙体的实验得到验证。本研究所构建的双向解析模型可作为高效可靠的工具，用于线材定向能量沉积工艺的评估与工艺设计。