Modeling of thermal and solidification behavior during laser additive manufacturing of AlSi10Mg alloy powders and its experimental validation

Abstract

In the present era, the laser additive manufacturing process is widely adopted in the manufacturing sector to produce near net shape components with minimum wastage of raw materials. Direct metal laser sintering (DMLS) is one of the laser additive manufacturing techniques which has received the most attention, as it builds the parts directly from metal or alloy powders. However, the quality of the components produced by DMLS has hindered its use on a larger scale. The process parameters in the DMLS process directly influence the quality of the building part. So, a better understanding of the influence of process parameters on build parts can provide insight to get high-quality products. In the present study, a three-dimensional transient heat transfer model was developed to simulate the temperature field and molten pool profile using the ansys 17.0 platform. The temperature distribution, melt pool dimension, solidification rate, cooling rate, and structural morphology are investigated with the variation of input laser energy. From the investigation, it was observed that the temperature of the powder bed and melt pool dimensions such as length, width, and depth increases with an increase in input laser energy. The cooling rate also increases with a decrease in laser energy input. Further, the developed model is validated to verify the accuracy and the simulated results are quite agreed with the analytical as well as experimental results.

Coupled mechanisms of the keyhole, energy transfer and compositional change associated with the variable polarity plasma arc process

“…The AlSi10Mg alloy contains a small quantity of Mg (0.3 wt%-0.5 wt%), which induced a hardening effect via the generation of Mg 2 Si precipitates. The selective laser-melting process is usually adopted for the fabrication of small AlSi10Mg alloy components, where Mg easily evaporates [46]. If the VPPAbased additive manufacturing is used, element loss from the bead can be suppressed.…”

Micro groove cutting on the surfaces of Cu-B4C nanocomposites by fiber laser

“…Various techniques are attempted to envisage the kerf size deviation of the laser micromachined Ti alloy (Ti-6Al-4V) sheet. The rise in laser frequency appreciably increases the kerf size and the deviations are decreased by introducing gas pressure [35]. Copper and its alloys are most often used in the micro-domain applications of personal computing and telecom industries.…”