The melt pool calculating method is presented based on the solution of the heat conduction problem in a three-dimensional formulation, taking into account the latent heat of fusion and the change in thermophysical properties with temperature. In this case, the phase transitions of melting and crystallization are accounted for using the source method. Considering the latent heat of fusion in the heat transfer process leads to melt pool elongation, as well as to a slight decrease in its width and depth. Depending on the mode, the melt pool elongation can be up to 22%. The penetration depth is reduced by about 5%. The deposition width does not change practically. The presented model was validated by comparing the experimentally determined melt pool shape and its dimensions with the corresponding theoretically calculated results. Experimental data were obtained as a result of coaxial video recording and the melt pool crystallization. The calculated form of the crystallization isotherm changes from a U-shape to a V-shape with an increase in the power and speed of the process, which coincides with the experimental data.
Keywords: additive manufacturing; enthalpy; latent heat; mushy zone; phase change.