A laser metal deposition (LMD) process is one of the directed energy deposition (DED) processes.
During LMD the supplied metal in the form of powder or wire is deposited layer by layer on topof each other to produce metal products. The LMD process is characterized by the rapidtemperature changes in the deposition area. Thermal fluctuation is the main cause of excessiveresidual stress in the vicinity of deposited region. Additionally, residual stress characteristics areaffected by the dimensions of deposited part. The purpose of this thesis is to investigate theresidual stress characteristics in the vicinity of deposited region based on substrate shape ofdeposited region when repairing an axially symmetrical metal parts by LMD process usingtwo-dimensional finite element analysis. From FEA results, the effects of substrate design includingthe deposition region inclination slope, depth and edge length in heat transfer, deformation andresidual stress characteristics of the laminated area was investigated. It was found that the smallerthe inclination slope of the substrate and the deeper the substrate depth and the longer thesubstrate edge length, the lower the residual stress. Increase of inclination slope, depth and edgelength results in larger deposition volume. It was concluded that increase of the volume ofdeposited material results in lower stresses due to tempering effect on the substrate and depositionregion. Based on the results of the analysis an appropriate design of the substrate is proposed.