An Efficient Track-Scale Model for Laser Powder Bed Fusion Additive Manufacturing: Part 1- Thermal Model

Tangestani, Reza; Sabiston, Trevor; Chakraborty, Apratim; Muhammad, Waqas; Yuan, Lang; Martin, Étienne

doi:10.3389/fmats.2021.753040

Cited by 13 publications

(15 citation statements)

References 39 publications

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“…In this model, the laser's thermal energy input is depicted as a heat source having a Gaussian distribution that progressively diminishes as it moves through the depth of the powder. The energy input is described in Eq.4 [33].…”

Section: Ed Heat Source Modelmentioning

confidence: 99%

“…The model has a 10% precision for predicting the temperature field while having an error of 10 ~25% for molten pool dimension prediction. Tangestani et al [33] developed a 3D exponentially-decaying track-scale model for LPBF process to consider the depth to which heat penetrates within the powder. The model accounts for the effect of powder state during the simulation.…”

Section: Introductionmentioning

confidence: 99%

“…Also, a deviation of 5μm predicting the melt pool depth and a 5% error while predicting the temperature distribution below the solidus temperature was reported. Although the model developed by Tangestani et al [33] uses an isotropic thermal conduction, it still lacks the precision to accurately predict the melt pool dimensions specially the width. On top of that the material state transition problem during the track-scale model has not been addressed practically.…”

Section: Introductionmentioning

confidence: 99%

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Track-scale Anisotropic Thermal Material Model as a Viable Substitution In Selective Laser Melting

Deldar Masrour,

Tangestani,

Farrahi

et al. 2023

JDAF

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High temperature gradients and resulting residual stresses are the main sources of defects such as cracks, distortion and fatigue failure is selective laser melting. In this paper, a new material model utilizing anisotropic thermal conduction model and track-scale heat input model is used to predict the melt pool geometry, material state and thermal history during the SLM process of SS316L in a large range of laser parameters. The model takes into consideration both the material state and the issue of phase transition during the track-scale simulation.. The simulated melt pools in the beam-scale and track-scale simulations are compared with experimental measurements in different laser parameters. It is found that the proposed material model is able to maintain accuracy between the beam-scale and track-scale simulations at an average of 5μm regarding melt pool dimensions. Furthermore, It can be inferred that both track-scale and beam-scale models exhibit the capability to provide precise predictions of melt pool geometries when compared to experimental measurements while the former being about 100 times faster than the latter. An average error of 10% was concluded for the material state comparison of the two models while the track-scale model was able to capture the temperature profile and cooling rate accurately in comparison with the beam-scale model.

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Section: Ed Heat Source Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Track-scale Anisotropic Thermal Material Model as a Viable Substitution In Selective Laser Melting

Deldar Masrour,

Tangestani,

Farrahi

et al. 2023

JDAF

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“…The laser spot diameter generally ranges from 50 to 250 μm for LPBF and 0.3-3 mm for LDED and is often a physically set value. [31,32] For EPBF, the focus offset is adjusted by changing the electromagnetic lens system current flow, and the resultant electron-beam spot diameter is often several hundred μm. [28,32] A larger spot diameter results in energy distribution over a larger area, which means a higher laser or electron-beam power and/or lower scan speed are necessary for single-track powder consolidation in PBF processes.…”

Section: Processing Solidification Defects and Microstructure Of Addi...mentioning

confidence: 99%

Heat‐Resistant Intermetallic Compounds and Ceramic Dispersion Alloys for Additive Manufacturing: A Review

Yakubov

Kruzic

2022

Adv Eng Mater

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Many industries such as aerospace, power generation, and ground transportation demand structural materials with high specific strength at elevated temperatures. Up until now, many types of heat‐resistant materials including Ni‐based superalloys, intermetallic compounds, and dispersion‐strengthened alloys have been developed for specific applications in these industries. Moreover, with the recent development of additive manufacturing techniques, these industries can now benefit from the rapid prototyping abilities, geometric freedom, and increased mechanical properties that can be achieved through various additive manufacturing processes. With this in mind, the progress made in additive manufacturing of heat‐resistant intermetallic compounds and ceramic dispersion alloys is herein examined. A brief introduction is provided on the target industries, applications, and the compositions of heat‐resistant alloys of current research interest. Then, recent research on heat‐resistant intermetallic compounds and ceramic dispersion alloys fabricated by additive manufacturing processes such as laser powder bed fusion, laser direct energy deposition, and electron‐beam powder bed fusion are reviewed with information provided on microstructure, processing parameters, strengthening mechanisms, and mechanical properties. Finally, an outlook is provided with future research suggestions.

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“…Despite all these advantages compared to the conventional machining methods, this process is affected by low efficiency in terms of material handling, high maintenance costs and low production volume [13]. The build rate of L-PBF is roughly estimated to be around 40 cm 3 /h, lower than that estimated for electron beam melting (EBM) and direct energy deposition (DED) of 70-100 and 140 cm 3 /h, respectively [14].…”

Section: Introductionmentioning

confidence: 99%

Study on the Effect of Inter-Layer Cooling Time on Porosity and Melt Pool in Inconel 718 Components Processed by Laser Powder Bed Fusion

Baldi

Giorgetti

Palladino³

et al. 2023

Materials

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This paper investigates the effects on the material microstructure of varying the Inter-Layer Cooling Time (ILCT) during the printing process in laser powder bed fusion (L-PBF) multi-laser machines. Despite these machines allowing higher productivity rates compared to single laser machines, they are affected by lower ILCT values, which could be critical for material printability and microstructure. The ILCT values depend both on the process parameter sets and design choices for the parts and play an important role in the Design for Additive Manufacturing approach in L-PBF process. In order to identify the critical range of ILCT for this working condition, an experimental campaign is presented on the nickel-based superalloy Inconel 718, which is widely used for the printing of turbomachinery components. The effect of ILCT on the microstructure of the material is evaluated in terms of porosity and melt pool analysis on printed cylinder specimens, considering ILCT decreasing and increasing in the range of 22 to 2 s. The experimental campaign shows that an ILCT of less than 6 s introduces criticality in the material microstructure. In particular, at an ILCT value of 2 s, widespread keyhole porosity (close to 1‰) and critical and deeper melt pool (about 200 microns depth) are measured. This variation in melt pool shape indicates a change in the powder melting regime and, consequently, modifications of the printability window promoting the expansion of the keyhole region. In addition, specimens with geometry obstructing the heat flow have been studied using the critical ILCT value (2 s) to evaluate the effect of the surface-to-volume ratio. The results show an enhancement of the porosity value (about 3‰), while this effect is limited for the depth of the melt pool.

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An Efficient Track-Scale Model for Laser Powder Bed Fusion Additive Manufacturing: Part 1- Thermal Model

Cited by 13 publications

References 39 publications

Track-scale Anisotropic Thermal Material Model as a Viable Substitution In Selective Laser Melting

Track-scale Anisotropic Thermal Material Model as a Viable Substitution In Selective Laser Melting

Heat‐Resistant Intermetallic Compounds and Ceramic Dispersion Alloys for Additive Manufacturing: A Review

Study on the Effect of Inter-Layer Cooling Time on Porosity and Melt Pool in Inconel 718 Components Processed by Laser Powder Bed Fusion

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