Abstract
This paper presents an initial investigation into the numerical modeling of additive manufacturing processes for AlNiCo magnets. The research concentrated on calibrating the heat source parameters by utilizing previously published experimental results. The influence of laser power and scanning speed on the laser fusion of AlNiCo5 on SS 304 substrates was investigated through single track experiments. The geometries of the melt pools were measured and utilized as the foundation for model calibration. A two-step calibration methodology was adopted: (1) a simplified 2D model implemented in Octave was used for sensitivity analysis and parameter fitting; and (2) validation was performed using a 3D model within the commercial software Simufact Welding software. Parameters calibrated through 2D simulations could be directly transferred to the 3D context. However, while the calibration procedure enabled accurate fitting for individual tracks, it resulted in globally non-optimal parameters, suggesting that process parameters influence laser penetration depth.