Analytical modelling of scanning strategy effect on temperature field and melt track dimensions in laser powder bed fusion

Zagade, Pramod R.; Gautham, B.P.; De, Amitava; DebRoy, Tarasankar

doi:10.1016/j.addma.2024.104046

Cited by 3 publications

(6 citation statements)

References 53 publications

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“…The temperature gradient indicates the difference between the temperature at the testing point and the surrounding area, which depends on the overall average layer temperature increase and the effect of the previous scanning [ 41 ]. In general, a full circulation of scanning would lead to a higher average layer temperature, thus resulting in lower maximum temperature gradients at certain points; for example, point b in strategy A , where the laser head scans a full circulation at one time, has a maximum temperature gradient of about

, but in strategy G , where the laser head scans with a quarter circulation at one time, this value is increased to

.…”

Section: Resultsmentioning

confidence: 99%

“…Based on previous research, the possible influence of scanning strategy can be attributed to differences in scanning track length, direction, Out–In or In–Out strategy, start point, etc. [ 41 ]. To investigate the effects of these scanning strategy-related variables, a total of eight scanning strategies were designed, as shown in Figure 6 .…”

Section: Methodsmentioning

confidence: 99%

“…Another important factor that could influence the temperature and stress fields during SLM is the scanning strategy: how the laser head scans the powders within each layer. Its influence has also been studied by previous researchers: Pramod R. Zagade et al [ 41 ] built an analytical model to reveal the effect of scanning strategy on the temperature field and melt track dimensions; Peiying Bian et al, as well as Zhijun Zheng et al, conducted simulations and experiments to investigate how the scanning strategy influences the residual stress [ 42 ] and manufacturing quality [ 43 ] of 316L steel; Jinbiao Zhou et al [ 44 ] studied the scanning strategy’s effect on the temperature history and residual stress of SLMed Ti-6Al-4V components; Xiaochuan Zhang et al [ 45 ] researched its effect on the stress and deformation of overhang structures. Various scanning strategies have been proposed.…”

Section: Introductionmentioning

confidence: 91%

“…For a plate, examples include stripe and chessboard (island) scanning strategies [ 42 ], unidirectional, bidirectional, and Out–In and In–Out strategies. [ 41 ] Moreover, the scanning strategy not only could vary within the same layer between different sets but also could vary between different layers within a single set, including different trajectories and starting points [ 44 ]. Their research revealed a close connection between residual stress and scanning strategy.…”

Section: Introductionmentioning

confidence: 99%

“…The contribution of this work can be summarized as follows, with an investigation into the current research and unresearched areas in this field: (a) Numerical models for thermal and mechanical behaviors during the SLM process have been well established and verified, but until now, most research was conducted based on SLMed block geometry, with scanning strategies designed accordingly for a plate layer [ 41 ]. However, SLM is usually used to manufacture more complex geometries, which require completely different scanning strategies.…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

The Effect of Scanning Strategy on the Thermal Behavior and Residual Stress Distribution of Damping Alloys during Selective Laser Melting

Yan,

Wu,

Xiao

et al. 2024

Materials

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The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along which the laser head scans powders within given area, is crucial, but clearly defined criteria for scanning strategy design are lacking. In this study, a three-dimensional finite element model (FEM) of the SLM process for manufacturing a WE43 alloy component was established and validated against the published experimental data. Eleven different scanning strategies were designed and simulated, considering variables such as scanning track length, direction, Out–In or In–Out strategy, start point, and interlayer variation. The results showed that scanning strategy, geometry, and layer number collectively affect temperature, melt pool, and stress outputs. For instance, starting scanning at a colder part of the powder layer could lead to a high peak temperature and low melt pool depth. A higher layer number generally results in lower cooling rate, a lower temperature gradient, a longer melt pool life, and larger melt pool dimensions. Changing the start point between scanning circulations helps mitigate detrimental residual stress. This work highlights the potential of analyzing various scanning strategy-related variables, which contributes to reducing trial-and-error tests and selecting optimal scanning strategies under different product quality requirements. This article can assist in the design of appropriate scanning strategies to prevent defects such as element loss due to evaporation, poor bonding, and deformation or cracking from high residual stress. Additionally, identifying stress concentration locations and understanding the effects of geometry and layer number on thermal and mechanical behaviors can assist in geometry design.

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, but in strategy G , where the laser head scans with a quarter circulation at one time, this value is increased to

.…”

Section: Resultsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%