Direct metal deposition (DMD) with coaxial powder injection allows fabrication of three-dimensional geometry with rapidly solidified microstructure. During DMD, addition of powder leads to the interaction between laser and powder, and also the redistribution of solute. The concentration distribution of the alloying element is very important for mechanical properties of the deposited clad material. The evolution of concentration distribution of carbon and chromium in the molten pool is simulated using a self-consistent three-dimensional model, based on the solution of the equations of mass, momentum, energy conservation and solute transport in the molten pool. The experimental and calculated molten pool geometry is compared for model validation purposes. (C) 2011 Elsevier B.V. All rights reserved.