Multiphase transport and compositional mixing mechanisms in twin-wire laser directed energy deposition: toward process stability and graded material fabrication
Twin-wire laser directed energy deposition (TW-LDED) provides a promising route for alloying and fabrication of compositionally graded structures. However, inherent multiparameter coupling in twin-wire systems critically exacerbates both process instabilities and compositional inhomogeneity. This unresolved issue escalates into a fundamental technological bottleneck, as the underlying physical mechanisms remain poorly understood. This study developed a high-fidelity multi-physics and multiphase simulation framework coupled with experimental validation to reveal thermal-fluid behavior and heat-mass transfer mechanisms in TW-LDED using Inconel 718 and SS316L fine wires. Three distinct transition modes were identified: twin-wire melt droplet, twin-wire liquid bridge, and droplet-bridge mixed transitions, with the twin-wire liquid bridge regime delivering optimal stability and uniform mixing. Parametric analysis demonstrates that increasing wire feeding speed or decreasing wire initial height promotes stable liquid bridge formation, while small laser spots at low feeding speeds induce excessive volumetric energy density and bridge instability. Simulation and single-track experiments confirm that liquid bridge transitions reduce dimensional fluctuations by 85% while enhancing compositional homogeneity. Conversely, the melt droplet-bridge transition mode creates periodic flow switching and compositional discontinuities along the scan direction. Finally, a 60 mm functionally graded ring was successfully fabricated using optimized parameters, achieving uniform elemental distribution in the transition zone without significant segregation, validating the feasibility of TW-LDED for functionally graded components.