Experimental, computational, and data-driven study of the effects of selective laser melting (SLM) process parameters on single-layer surface characteristics

Fotovvati, Behzad; Rauniyar, Santosh; Arnold, Jobe A.; Chou, Kevin

doi:10.1007/s00170-022-10167-6

Cited by 6 publications

(1 citation statement)

References 74 publications

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“…However, the benefits of PBF technology come at a price. During manufacturing, PBF induces multiple interconnected multi-physics phenomena to co-occur simultaneously, locally, and within very short timescales, including melting and re-melting, the evaporation and emission of a material, directional solidification, chemical reactions, thermo-capillarity, surface tension, and many others [7,8]. The complex physics of PBF which is closely linked with numerous process parameters [9,10] affects the final product's microstructure and properties and makes the PBF process challenging to control.…”

Section: Introductionmentioning

confidence: 99%

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Zinovieva,

Romanova,

Dymnich

et al. 2023

Materials

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In the rapidly evolving field of additive manufacturing (AM), the predictability of part properties is still challenging due to the inherent multiphysics complexity of the technology. This results in time-consuming and costly experimental guess-and-check approaches for manufacturing each individual design. Through synthesising advancements in the field, this review argues that numerical modelling is instrumental in mitigating these challenges by working in tandem with experimental studies. Unique hierarchical microstructures induced by extreme AM process conditions– including melt pool patterns, grains, cellular–dendritic substructures, and precipitates—affect the final part properties. Therefore, the development of microstructure-informed mechanical models becomes vital. Our review of numerical studies explores various modelling approaches that consider the microstructural features explicitly and offers insights into multiscale stress–strain analysis across diverse materials fabricated by powder bed fusion AM. The literature indicates a growing consensus on the key role of multiscale integrated process–structure–property–performance (PSPP) modelling in capturing the complexity of AM-produced materials. Current models, though increasingly sophisticated, still tend to relate only two elements of the PSPP chain while often focusing on a single scale. This emphasises the need for integrated PSPP approaches validated by a solid experimental base. The PSPP paradigm for AM, while promising as a concept, is still in its infantry, confronting multifaceted challenges that require in-depth, multidisciplinary expertise. These challenges range from accounting for multiphysics phenomena (e.g., advanced laser–material interaction) and their interplay (thermo-mechanical and microstructural evolution for simulating Type II residual stresses), accurately defined assumptions (e.g., flat molten surface during AM or purely epitaxial solidification), and correctly estimated boundary conditions for each element of the PSPP chain up to the need to balance the model’s complexity and detalisation in terms of both multiphysics and discretisation with efficient multitrack and multilayer simulations. Efforts in bridging these gaps would not only improve predictability but also expedite the development and certification of new AM materials.

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Section: Introductionmentioning

confidence: 99%

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Zinovieva,

Romanova,

Dymnich

et al. 2023

Materials

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The effect of process parameters on the stability and efficiency in the laser powder bed fusion of Ti-6Al-4 V based on the interval powder layer thickness

Wang

Chen

Tang³

et al. 2023

Int J Adv Manuf Technol

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An extended laser beam heating model for a numerical platform to simulate multi-material selective laser melting

Dmytro,

Szymon,

Michal

2023

Int J Adv Manuf Technol

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A laser beam heating model (LBHM) is an important part of a platform for numerical modelling of a multi-material selective laser melting process. The LBHM is utilised as a ray-tracing algorithm that is widely applied for rendering in different applications, mainly for visualisation and very recently for laser heating models in selective laser melting. The model presented in this paper was further extended to transparent and translucent materials, including materials where transparency is dependent on the material temperature. In addition to reflection and surface absorption, commonly considered in such models, phenomena such as refraction, scattering and volume absorption were also implemented. Considering associated energy transfer, the model represents a laser beam as a stream of moving particles, i.e. photons of the same energy. When the photons meet a boundary between materials, they are reflected, absorbed or transmitted according to geometric and thermal interfacial characteristics. This paper describes the LBHM in detail, its verification and validation, and also presents several simulation examples of the entire selective laser melting process with implemented LBHM.

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Experimental, computational, and data-driven study of the effects of selective laser melting (SLM) process parameters on single-layer surface characteristics

Cited by 6 publications

References 74 publications

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

The effect of process parameters on the stability and efficiency in the laser powder bed fusion of Ti-6Al-4 V based on the interval powder layer thickness

An extended laser beam heating model for a numerical platform to simulate multi-material selective laser melting

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