Research on interlayer remelting process of multi-layer forming by metal fused-coating additive manufacturing

In order to achieve good interlayer metallurgical bonding in the metal fused-coating additive manufacturing, the finite element thermal analysis model was established and the influences of different heating temperatures of fused coating nozzle and substrate on the interlayer remelting was analyzed. The maximum remelting depth under different temperature conditions was obtained. The multi-layer forming experiments were performed under different temperature conditions, and the results showed that increasing the heating temperature of nozzle or substrate will effectively increase the remelting depth, that the surface forming quality is better when the remelting depth is in the range of 0.1 similar to 0.2 mm, and that the deviation between the remelting depth and the calculated value is less than 15 %. So, the model can predict the remelting depth of the intermetallic microstructure.