Influence of oscillating laser on forming characteristics and molten pool flow behavior of aluminum alloy double-wire additive manufacturing

A new laser additive manufacturing approach is proposed in this paper by combining oscillating laser with double-wire additive manufacturing to improve additive efficiency and shape. The feasibility of the approach is experimentally verified, and the corresponding simulation model is proposed. The model considers the effects of surface tension, recoil pressure, gravity, and Marangoni force as well as continuous wire feeding. Simulation results are in good agreement with the experimental ones, which verifies the accuracy of the simulation model. The characteristics of temperature and flow fields and forming laws of different oscillating methods in the additive manufacturing process are compared and analyzed by simulation models. The study shows that the melt pool shape, temperature characteristics, and molding morphology of different oscillating methods considerably vary under the same process parameters. Among them, the circular oscillating peak temperature and maximum temperature gradient are low and the molding morphology is the best.