Modeling and Mechanistic Analysis of Molten Pool Evolution and Energy Synergy in Laser–Cold Metal Transfer Hybrid Additive Manufacturing of 316L Stainless Steel

The present work uses numerical methods to explore the impact of spatial orientation on the behavior of molten pool and thermal responses during the laser–Cold Metal Transfer (CMT) hybrid additive manufacturing of metallic cladding layers. Based on the traditional double-ellipsoidal heat source model, an adaptive CMT arc heat source model was developed and optimized using experimentally calibrated parameters to accurately represent the coupled energy distribution of the laser and CMT arc. The improved model was employed to simulate temperature and velocity fields under horizontal, transverse, vertical-up, and vertical-down orientations. The results revealed that variations in gravity direction had a limited effect on the overall molten pool morphology due to the dominant role of vapor recoil pressure, while significantly influencing the local convection patterns and temperature gradients. The simulations further demonstrated the formation of keyholes, dual-vortex flow structures, and Marangoni-driven circulation within the molten pool, as well as the redistribution of molten metal under different orientations. In multi-layer deposition simulations, optimized heat input effectively mitigated excessive thermal stresses, ensured uniform interlayer bonding, and maintained high forming accuracy. This work establishes a comprehensive numerical framework for analyzing orientation-dependent heat and mass transfer mechanisms and provides a solid foundation for the adaptive control and optimization of laser–CMT hybrid additive manufacturing processes.