Modeling and numerical studies of high-precision laser powder bed fusion

Author:

Wei Yi123ORCID,Chen Genyu23,Tao Nengru123,Zhou Wei23

Affiliation:

1. School of Intelligent Manufacturing, Hunan First Normal University 1 , Changsha 410221, China

2. College of Mechanical and Vehicle Engineering, Hunan University 2 , Changsha 410082, China

3. Institute of Laser Technology, Hunan University 3 , Changsha 410082, China

Abstract

In order to comprehensively reveal the evolutionary dynamics of the molten pool and the state of motion of the fluid during the high-precision laser powder bed fusion (HP-LPBF) process, this study aims to deeply investigate the specific manifestations of the multiphase flow, solidification phenomena, and heat transfer during the process by means of numerical simulation methods. Numerical simulation models of SS316L single-layer HP-LPBF formation with single and double tracks were constructed using the discrete element method and the computational fluid dynamics method. The effects of various factors such as Marangoni convection, surface tension, vapor recoil, gravity, thermal convection, thermal radiation, and evaporative heat dissipation on the heat and mass transfer in the molten pool have been paid attention to during the model construction process. The results show that the molten pool exhibits a “comet” shape, in which the temperature gradient at the front end of the pool is significantly larger than that at the tail end, with the highest temperature gradient up to 1.69 × 108 K/s. It is also found that the depth of the second track is larger than that of the first one, and the process parameter window has been determined preliminarily. In addition, the application of HP-LPBF technology helps to reduce the surface roughness and minimize the forming size.

Funder

Department of science and technology of guangdong province

China Postdoctoral Science Foundation

Natural Science Foundation of Hunan Province

Publisher

AIP Publishing

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