Multi-physical simulation of selective laser melting

Leitz, Karl-Heinz; Singer, Péter; Plankensteiner, A.; Tabernig, B.; Kestler, H.; Sigl, Lorenz S.

doi:10.1016/j.mprp.2016.04.004

Cited by 59 publications

(24 citation statements)

References 8 publications

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“…Therefore, the sensitivity of the relative density to the three process parameters decreased according to the following order: laser power > scan speed > hatching distance. This result is consistent with previous results and could be ascribed to the special thermophysical properties of tungsten and tungsten heavy alloys [31]. In this section, the nearly full densification of the 90W-7Ni-3Fe sample fabricated by SLM was realized.…”

Section: Densification Analysissupporting

confidence: 92%

Densification, Microstructure and Properties of 90W-7Ni-3Fe Fabricated by Selective Laser Melting

Wei

Zhou

et al. 2019

Metals

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The preparation of refractory tungsten and tungsten alloys has always been challenging due to their inherent properties. Selective laser melting (SLM) offers a choice for preparing tungsten and tungsten alloys. In this work, 90W-7Ni-3Fe samples were prepared by selective laser melting and investigated. Different process parameter combinations were designed according to the Taguchi method, and volumetric energy density (VED) was defined. Subsequently, the effects of process parameters on densification, phase composition, microstructure, tensile properties, and microhardness were investigated. Nearly a full densification sample (≥99%) was obtained under optimized process parameters, and the value of VED was no less than 300 J/mm3. Laser power had a dominant influence on densification behavior compared with other parameters. The main phases of 90W-7Ni-3Fe are W and γ-(Ni-Fe), dissolved with partial W. In addition, 90W-7Ni-3Fe showed a high tensile strength (UTS = 1121 MPa) with poor elongation (<1%). A high average microhardness (>400 HV0.3) was obtained, but the microhardness presented a fluctuation along building direction due to the inhomogeneous microstructure.

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Section: Densification Analysissupporting

confidence: 92%

Densification, Microstructure and Properties of 90W-7Ni-3Fe Fabricated by Selective Laser Melting

Wei

Zhou

et al. 2019

Metals

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“…Some effort has been made in this field and a wide range of applications are reported in the literature, including but not limited to hardening [ 4 ], laser ablation [ 5 ], laser cutting [ 6 ], laser drilling [ 7 ], laser welding [ 8 , 9 ], and additive manufacturing of metal powder [ 10 , 11 ]. Irrespective of the application, the prediction of the temperature field is crucial for many purposes, including but not limited to non-destructive real-time evaluation of the process [ 2 ], minimization of residual stresses, and heat accumulation during additive manufacturing [ 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Simulation of Laser Heating of Aluminum and Model Validation via Two-Color Pyrometer and Shape Assessment

Alfieri

2018

Materials

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The modeling of laser-based processes is increasingly addressed in a competitive environment for two main reasons: Preventing a trial-and-error approach to set the optimum processing conditions and non-destructive real-time control. In this frame, a thermal model for laser heating in the form of non-penetrative bead-on-plate welds of aluminum alloy 2024 is proposed in this paper. A super-Gaussian profile is considered for the transverse optical intensity and a number of laws for temperature-dependent material properties have been included aiming to improve the reliability of the model. The output of the simulation in terms of both thermal evolution of the parent metal and geometry of the fusion zone is validated in comparison with the actual response: namely, a two-color pyrometer is used to infer the thermal history on the exposed surface around the scanning path, whereas the shape and size of the fusion zone are assessed in the transverse cross-section. With an average error of 3% and 4%, the model is capable of predicting the peak temperature and the depth of the fusion zone upon laser heating, respectively. The model is intended to offer a comprehensive description of phenomena in laser heating in preparation for a further model for repairing via additive manufacturing.

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“…The width of the laser track, which is strongly related to the scanning patch, is an important factor affecting the final material. Therefore, it is considered to be an effective verification method to compare the simulation width with experiments [ 48 ]. In order to verify the credibility of this model, two different experiments were conducted to observe the width of the melt channel.…”

Section: Resultsmentioning

confidence: 99%

Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy

2020

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A three dimensional finite element model (FEM) was established to simulate the temperature distribution, flow activity, and deformation of the melt pool of selective laser melting (SLM) AZ91D magnesium alloy powder. The latent heat in phase transition, Marangoni effect, and the movement of laser beam power with a Gaussian energy distribution were taken into account. The influence of the applied linear laser power on temperature distribution, flow field, and the melt-pool dimensions and shape, as well as resultant densification activity, was investigated and is discussed in this paper. Large temperature gradients and high cooling rates were observed during the process. A violent flow occurred in the melt pool, and the divergent flow makes the melt pool wider and longer but shallower. With the increase of laser power, the melt pool’s size increases, but the shape becomes longer and narrower. The width of the melt pool in single-scan experiment is acquired, which is in good agreement with the results predicted by the simulation (with error of 1.49%). This FE model provides an intuitive understanding of the complex physical phenomena that occur during SLM process of AZ91D magnesium alloy. It can help to select the optimal parameters to improve the quality of final parts and reduce the cost of experimental research.

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Multi-physical simulation of selective laser melting

Cited by 59 publications

References 8 publications

Densification, Microstructure and Properties of 90W-7Ni-3Fe Fabricated by Selective Laser Melting

Densification, Microstructure and Properties of 90W-7Ni-3Fe Fabricated by Selective Laser Melting

Simulation of Laser Heating of Aluminum and Model Validation via Two-Color Pyrometer and Shape Assessment

Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy

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