Identification of a suitable volumetric heat source for modelling of selective laser melting of Ti6Al4V powder using numerical and experimental validation approach

Mishra, Ashish Kumar; Aggarwal, Akash; Kumar, Arvind; Sinha, Niraj

doi:10.1007/s00170-018-2631-4

Cited by 38 publications

(12 citation statements)

References 28 publications

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“…In the overlap area, due to higher viscosity and mush phase, the interaction of surface tension and hydrostatic force versus vapour pressure is not balanced, and keyholes and fusion appear, hence increasing the value of surface roughness. Also, due to the lack of Marangoni's convection, accumulated heat increases the chance of cracks, more specifically when the temperature of the melting pool is high [37,38]. Moreover, in the case of lower hatch space due to higher overlap, some of the ripples were covered by the overlapping of subsequent hatching.…”

Section: Hatch Space and Pattern Anglementioning

confidence: 99%

A study on surface morphology and tension in laser powder bed fusion of Ti-6Al-4V

Khorasani

Ghasemi

Awan

et al. 2020

Int J Adv Manuf Technol

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When reporting surface quality, the roughest surface is a reference for the measurements. In LPBF due to recoil pressure and scan movement, asymmetric surface is shaped, and surface roughness has different values in different measurement orientations. In this research, the influence of the laser powder bed fusion (LPBF) process parameters on surface tension and roughness of Ti-6AI-4 V parts in three orientations are investigated. To improve the mechanical properties, heat treatment was carried out and added to the designed matrix to generate a comprehensive data set. Taguchi design of experiment was employed to print 25 samples with five process parameters and post-processing. The effect and interaction of the parameters on the formation of surface profile comprising tension, morphology and roughness in various directions have been analysed. The main contribution of this paper is developing a model to approximate the melting pool temperature and surface tension based on the process parameters. Other contributions are an analysis of process parameters to determine the formation and variation of surface tension and roughness and explain the governing mechanisms through rheological phenomena. Results showed that the main driving factors in the variation of surface tension and formation of the surface profile are thermophysical properties of the feedstock, rheology and the temperature of the melting pool. Also, the results showed that while the value of surface tension is the same for each test case, morphology and the value of roughness are different when analysing the surface in perpendicular, parallel and angled directions to laser movement.

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Section: Hatch Space and Pattern Anglementioning

confidence: 99%

A study on surface morphology and tension in laser powder bed fusion of Ti-6Al-4V

Khorasani

Ghasemi

Awan

et al. 2020

Int J Adv Manuf Technol

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“…Here, ρ 1 , ρ 2 and ρ 3 are the densities of the 304 stainless-steel, Al 2 O 3 and ZrO 2 powder components, respectively. ρ 0 is the density of the powder component at the ambient temperature [31,33,34]. Note that ρ powder = ρ bulk when φ = 0 at the melting point.…”

Section: Physical Properties Of Materialsmentioning

confidence: 99%

Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites

Abolhasani

Seyedkashi

Kang

et al. 2019

Metals

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The melt-pool behaviors during selective laser melting (SLM) of Al2O3-reinforced and a eutectic mixture of Al2O3-ZrO2-reinforced AISI 304 stainless-steel composites were numerically analyzed and experimentally validated. The thermal analysis results show that the geometry of the melt pool is significantly dependent on reinforcing particles, owing to the variations in the melting point and the thermal conductivity of the powder mixture. With the use of a eutectic mixture of Al2O3-ZrO2 instead of an Al2O3 reinforcing particle, the maximum temperature of the melt pool was increased. Meanwhile, a negligible corresponding relationship was observed between the cooling rate of both reinforcements. Therefore, it was identified that the liquid lifetime of the melt pool has the effect on the melting behavior, rather than the cooling rate, and the liquid lifetime increases with the eutectic ratio of Al2O3-ZrO2 reinforcement. The temperature gradient at the top surface reduces with the use of an Al2O3-ZrO2 reinforcement particle due to the wider melt pool. Inversely, the temperature gradient in the thickness direction increases with the use of an Al2O3-ZrO2 reinforcement particle. The results of melt-pool behaviors will provide a deep understanding of the effect of reinforcing particles on the dimensional accuracies and properties of fabricated AISI 304 stainless-steel composites.

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“…In recent years, as an emerging manufacturing technology, additive manufacturing (AM) technology has great developing potential in the global manufacturing industry, which has gained wide concentration. [1][2][3] Selective laser melting (SLM) is a typical additive manufacturing technology, the technology uses a laser heat source to melt metal powder to form a cladding layer and solidify it by heat dissipation into a high-performance metal part with a complex threedimensional structure. [4] Selective laser melted component has good mechanical properties such as strength of extension, elongation, Young's modulus, impact toughness and hardness.…”

Section: Introductionmentioning

confidence: 99%

Effect of supporting structure design on residual stresses in selective laser melting of AlSi10Mg

Jiang

Guo

et al. 2021

Int J Adv Manuf Technol

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：Residual stress is a key indicator to measure the forming quality of SLM components, and its control method has received extensive attention. As an auxiliary structure for forming SLM components, the structural characteristics of the supporting structure will affect the residual stress distribution of the formed parts. Therefore, it is extremely meaningful to explore the influence of the supporting structure design on the residual stress of SLM AlSi10Mg alloy. In this study, an approach is proposed to select and design the support structure for forming SLM components with different structural characteristics to achieve the purpose of reducing the residual stress in the overhanging structure of the components. As the result shows, when the contact area of single supporting tooth structure and component overhanging structure is 0.25mm 2 and the X/Y interval of main supporting structure is 2.5mm, the forming effect is relatively good. Furthermore, the block supporting structure is more suitable for the overhanging structure which has small areas and less height, and the contour support is more suitable for the overhanging structure with larger area.

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Identification of a suitable volumetric heat source for modelling of selective laser melting of Ti6Al4V powder using numerical and experimental validation approach

Cited by 38 publications

References 28 publications

A study on surface morphology and tension in laser powder bed fusion of Ti-6Al-4V

A study on surface morphology and tension in laser powder bed fusion of Ti-6Al-4V

Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites

Effect of supporting structure design on residual stresses in selective laser melting of AlSi10Mg

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