In Laser Material Deposition (LMD), the interaction between the laser beam and the powder particles plays a crucial role in the track formation process. The particle cloud partially obstructs the incident laser beam, resulting in a modified power density distribution that reaches the process plane. As the powder particles pass through the interaction zone, they absorb energy and contribute an additional heat flux to the process. The superposition of this heat flux with the laser-induced heat input can lead to a significantly different thermal profile compared to the original beam profile.

To systematically analyze these effects, a simulation model is developed that allows variation of key parameters, including the process plane position within the beam caustic, the relative alignment of the laser and powder beam foci, the beam profile, the grain size, and the mean particle velocity. The contribution of the two heat fluxes is also systematically adjusted. A statistical model for particle trajectories is employed, with model parameters calibrated to match experimentally measured particle density distributions. The beam propagation is modeled using geometrical optics, incorporating multiple reflections.

This approach provides deeper insights into the underlying physical mechanisms for different process configurations. Moreover, it enables the predictive selection of suitable process parameter sets through simulation, thereby optimizing LMD process efficiency and quality.