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An open source two-dimensional (2D) thermal finite element (FE) model of theDirected Energy Deposition (DED) process is developed using the Python-basedFEniCS framework. The model incrementally deposits material ahead of the laserfocus point according to the geometry of the part. The laser heat energy issupplied by a Gaussian-distributed heat source while the phase change isrepresented by increased heat capacity around the solidus-liquidus temperaturerange. Experimental validation of the numerical model is performed by matchingwith the melt pool temperature measurements taken by a dual wavelengthpyrometer during the build process of a box-shaped Ti--6Al--4V part with largegeometrical voids. Effects of large geometrical voids on the melt pool shapeand maximum melt pool temperature are examined. Both the numerical andexperimental data show an increase in the melt pool size and temperature duringdeposition above large voids. The trailing edge of the melt pool's temperatureprofile obtained using the developed numerical model closely matches pyrometermeasurements.

Two-dimensional thermal finite element model of directed energy deposition: matching melt pool temperature profile with pyrometer measurement