Research on Multiscale Numerical Simulation Method for SLM Melting Process

Abstract

In the selective-laser-melting process, it is difficult to monitor the evolution of the melt pool in real time via experimental methods due to the complexity and fine scale of laser–powder interaction; numerical simulation has become an important technical way to study the selective-laser-melting process. A coupled thermal–fluid model of the SLM single-layer melt-channel-forming process is constructed based on hydrodynamic theory for AlSi10Mg metallic materials, and the SLM single-layer melt-channel-forming process is investigated by combining parametric experiments and numerical simulation methods. A binarised spatial-random-function pore material model is proposed, and a multiscale finite-element numerical model of the melt-channel-forming process is constructed to compare and verify the first-layer melt-channel-forming process and to analyse the evolution of the melt pool and the change in the temperature field in multi-layer melt channel formation. The results of this study show that the multiscale numerical model of the SLM multilayer melt-channel-forming process has a reliable computational accuracy, with an average error of 6.77% for the melt pool length and 1.69% for the melt pool width; Marangoni convection effects increase the melt pool size, and the presence of pores significantly affects the evolution of the powder bed temperature field. With laser scanning and powder bed stacking, the overall temperature of the powder bed and the peak temperature of the molten pool gradually increased, and the length, width, and height dimensions of the molten pool increased by 44.9%, 21.7%, and 33.8%, respectively.