Study on the Numerical Simulation of the SLM Molten Pool Dynamic Behavior of a Nickel-Based Superalloy on the Workpiece Scale

Abstract

Nickel-based superalloys are one of the most industrially important families of metallic alloys at present. Selective Laser Melting (SLM), as one of the additive manufacturing technologies for directly forming complex metal parts, has been applied in the production of Inconel 718 components. Based on the more reasonable and comprehensive equivalent processing models (vaporization heat loss, equivalent physical parameters) for the nickel-based superalloy SLM process, an SLM molten pool dynamic behavior prediction model on the workpiece scale was established. Related equivalent processing models were customized by secondary development with the software Fluent. In order to verify the feasibility of the SLM molten pool dynamics model, the SLM single-pass employed to form the Inconel 718 alloy process was calculated. The simulated and experimental solidified track dimensions were in good agreement. Then, the influences of different process parameters (laser power, scanning speed) on the SLM formation of the Inconel 718 alloy were calculated and analyzed. The simulation and experimental solidified track widths were well-matched, and the result showed that, as a rule, the solidified track width increased linearly with the laser power and decreased linearly with the scanning speed. This paper will help lay the foundation for a subsequent numerical simulation study of the thermal-melt-stress evolution process of an SLM workpiece.