Computationally Efficient Modelling of Induction-based Preheating of Wire Feedstock for Additive Manufacturing

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Published: Jun 2, 2026
DOI: https://doi.org/10.59972/9hu7g7ag
Keywords:
Induction preheating, Additive manufacturing, Directed energy deposition, Lagrangian method, Eulerian method

Main Article Content

Ruofeng Cao
https://orcid.org/0009-0007-7768-5318
Yongle Sun
https://orcid.org/0000-0002-8401-8069
Wojciech Suder
https://orcid.org/0000-0003-1280-5431
Stewart Williams
https://orcid.org/0000-0002-4472-9747

Abstract

Wire-based directed energy deposition (DED) additive manufacturing (AM) uses an intense energy source to melt metal wire feedstock and is capable of efficiently depositing large-scale components. Wire preheating is promising to enhance the DED process productivity and part quality. Induction heating (IH) is a controllable non-contact method for rapidly and precisely preheating the wire feedstock, thereby significantly increasing the deposition rate. However, IH-based preheating of moving wire feedstock is complicated and underexplored for AM applications. In this study, to understand the complex electromagnetic heating mechanism, a multiphysics finite element model of coupled electromagnetic and thermal fields was developed based on the formulation in Eulerian frame, which improves the computational efficiency by 80.9 % compared to the model in Lagrangian frame. Furthermore, in the case of wire feedstock passing through a stationary magnetic field at a constant feed speed, a more efficient steady-state approach was proposed with 98.9 % computational time saving than the transient model. The temperature prediction by the model was validated by thermocouple measurement in an experiment. A range of coil geometries and setups were evaluated using the developed efficient model, revealing the coil effects on the wire preheating temperature and energy transfer.

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Computationally Efficient Modelling of Induction-based Preheating of Wire Feedstock for Additive Manufacturing. (2026). Engineering Modelling, Analysis and Simulation, 4(1). https://doi.org/10.59972/9hu7g7ag
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Vol. 4 No. 1 (2027): Issue 4
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How to Cite

Computationally Efficient Modelling of Induction-based Preheating of Wire Feedstock for Additive Manufacturing. (2026). Engineering Modelling, Analysis and Simulation, 4(1). https://doi.org/10.59972/9hu7g7ag

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