High-Fidelity Simulations and Statistical Overloading for Examining Laser Powder-Based Directed Energy Deposition Systems

We conduct turbulence-resolving, Euler-Lagrange Large Eddy Simulations with statistical overloading of a Laser Powder-Based Direct Energy Deposition (DED) setup. The low volume fraction of the dispersed phase (metal powder) allows for one-way coupling, enabling the use of statistical overloading. We start with a cold flow setup and then investigate the heat transfer effects of the laser beam on the powder stream. We consider a range of particle sizes and densities and track particle trajectories. A dynamic Smagorinsky model is used to resolve the sub-grid scales as well as a Langevin model to account for particle Brownian motion.