Abstract

The objective of this project was to develop and implement a procedure for validating finite element simulations applied to the Laser Metal Deposition using powder (LMD Powder) Additive Manufacturing process. An experimental methodology was designed, covering the study of LMD Powder technology, experimental setup, model calibration, and final validation.

First, the main characteristics of the LMD Powder process were studied, with particular emphasis on its thermal behaviour. Based on this analysis, the experimental setup was defined, including substrate design, thermocouple selection and positioning, and process window definition. An initial experimental campaign was then conducted to record the temperature evolution in the substrate during the deposition of several laser-melted layers. The resulting temperature data were used to calibrate the finite element thermal model.

For model validation, a second experimental campaign was carried out using a different manufacturing geometry. The experimental and simulation results were compared using predefined quality indicators to assess the accuracy of the calibrated model and determine whether recalibration was required.

Finally, a MATLAB code was developed to automate the analysis and comparison of experimental and simulation data, facilitating the validation process. The tool also enabled the generation of substrate heat maps based on the temperatures recorded by the thermocouples, providing a visual representation of the thermal distribution during the manufacturing process.