Simulation of the multi-beam electron-beam wire-feed additive manufacturing process in a vacuum

The paper considers modelling the wire deposition process with vertically fed wire by several symmetrically acting heat sources. We proposed the mathematical model to describe the above process, considering surface tension force, Marangoni force, vapor pressure force, and heat loss on evaporation. To solve the mathematical model, we use the smoothed particle hydrodynamics method. We carried out a series of numerical experiments for modelling the melting process of vertically fed wire with two symmetrically acting heat sources with different power and direction of action of heat sources. We found that vertical wire feeding provides uniform heating with the absence of shaded areas and flexible control of heat input into the metal. On the other hand, the weld bead geometry characteristics significantly depend on the heat sources’ power and direction.