Numerical simulation for electron beam selective melting PBF additive manufacturing of molybdenum

Zafar, Muhammad Qasim; Wu, Chwan-Hwa; Zhao, Haiyan; Du, Kui; Gong, Qianming

doi:10.1007/s00170-021-07671-6

Cited by 6 publications

(8 citation statements)

References 45 publications

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“…Accurate temperature history for each cladding layer is imperative for efficient prediction of residual stress and distortion [ 10 ]. The graphical representation ( Figure 10 ) of time–temperature history curves for the first layer, fifth layer, and eighth layer of cladding shows convergence in thermal distribution and the subsequent peak temperatures are approximately 1497 °C.…”

Section: Resultsmentioning

confidence: 99%

“…Optimum laser cladding parameters derived from an experimental campaign and subsequent energy density, scan velocity, and powder streaming combinations, are opted for single-track consolidations, and the corresponding melt pool size is monitored. Melt pool width is approximated with cladding width and depth up to the solidified region in the experimental trial [ 10 ]. Fabricated chunks are chosen through several inspection steps.…”

Section: Methodsmentioning

confidence: 99%

“…The traditional hit-and-trial approach is expensive and time-consuming; however, numerical simulation has expedited the process and performance comprehension for additively manufactured components [ 9 , 10 , 11 ]. Persuasive thermomechanical simulation depends on the accuracy of the numerical model, mesh convergency, material modeling, heat source configuration, and boundary conditions [ 7 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

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Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

et al. 2023

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Laser cladding has emerged as a promising technique for custom-built fabrications, remanufacturing, and repair of metallic components. However, frequent melting and solidification in the process cause inevitable residual stresses that often lead to geometric discrepancies and deterioration of the end product. The accurate physical interpretation of the powder consolidation process remains challenging. Thermomechanical process simulation has the potential to comprehend the layer-by-layer additive process and subsequent part-scale implications. Nevertheless, computational accuracy and efficacy have been serious concerns so far; therefore, a hybrid FEM scheme is adopted for efficient prediction of the temperature field, residual stress, and distortion in multilayer powder-fed laser cladding of Inconel®718. A transient material deposition with powder material modeling is schematized to replicate the fabrication process. Moreover, simulation results for residual stress and distortion are verified with in-house experiments, where residual stress is measured with XRD (X-Ray Diffraction) and geometric distortion is evaluated with CMM (Coordinate Measuring Machine). A maximum tensile residual stress of 373 ± 5 MPa is found in the vicinity of the layer right in the middle of the substrate and predicted results are precisely validated with experiments. Similarly, a 0.68 ± 0.01 mm distortion is observed with numerical simulation and showed a precise agreement with experimental data for the same geometry and processing conditions. Conclusively, the implemented hybrid FEM approach demonstrated a robust and accurate prediction of transient temperature field, residual stresses, and geometric distortion in the multilayer laser cladding of Inconel®718.

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Section: Resultsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

et al. 2023

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“…431−433 In this respect, the EBSM technique is particularly suitable for printing highly reflective and high melting point materials. Zafar et al 434 simulated the melt pool characteristics of highenergy EBSM. It was concluded that the heat input of 1200 J/ mm 3 is adequate to consolidate pore-free solid parts.…”

Section: Additive Manufacturing (Am)mentioning

confidence: 99%

“…Compared with SLM, EBSM has a finer microstructure and lower residual stress, which is beneficial for reducing cracking during fabrication. − In this respect, the EBSM technique is particularly suitable for printing highly reflective and high melting point materials. Zafar et al simulated the melt pool characteristics of high-energy EBSM. It was concluded that the heat input of 1200 J/mm 3 is adequate to consolidate pore-free solid parts.…”

Section: Phase Change For Other Purposesmentioning

confidence: 99%

Recent Advances in CFD Simulations of Multiphase Flow Processes with Phase Change

Zhu

Zhang

et al. 2023

Ind. Eng. Chem. Res.

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Phase change is a phenomenon that has been extensively utilized in chemical engineering, energy, electronics, vehicle, and space exploration. From both the science and engineering perspectives, gaining a profound understanding of the intricacies of multiphase flow processes accompanied by heat and mass transfer due to phase change is of fundamental importance. Indeed, the computational fluid dynamics (CFD) has been increasingly applied as an effective tool to give an in-depth and efficient analysis of the phase change processes, thereby enhancing our understanding and capacity to control and optimize the phase change effects in these processes. This paper seeks to provide a comprehensive review of the utilization of CFD methodologies in the simulations of phase change flows across various applications, including temperature management, drying, separation and purification, and others. First, the CFD models at various scales that are developed to elucidate the phase change processes are summarized. Second, the noteworthy advances in the recent CFD simulation work on various phase change processes are presented, respectively. Finally, the challenges and potential prospects to facilitate the application of the phase change flow are discussed. The current review aims to offer insightful guidance for the CFD modeling of phase change processes in numerous engineering application scenarios.

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Powder‐Based Additive Manufacturing: A Critical Review of Materials, Methods, Opportunities, and Challenges

Shanthar,

Chen,

Abeykoon

2023

Adv Eng Mater

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As a 0‐dimensional moulding material, powder particles can realise the construction of most engineering parts and can further improve the precision moulding and high‐performance manufacturing capabilities of additive manufacturing (AM). Therefore, the powder‐based additive manufacturing methods provide an outstanding practical value and development for modern manufacturing world. However, powder materials that are utilised in additive manufacturing continue to face challenges such as a lack of accessible categories, temperature restrictions, and poor performance of moulded components. Therefore, researching for new additive manufacturing materials and procedures has become one of the important and influential ways to accelerate the progress of additive manufacturing technology and also to expand its application fields. For this purpose, it is invaluable to understand and update on the current state‐of‐the‐art of powder‐based additive manufacturing technologies. Hence, this work first reviews the research background of powder‐based 3D printing in details while systematically expounding on the technologies and equipment, material types, influencing factors, existing problems and development trends of powder‐based 3D printing. In addition, the basic principles of powder‐based 3D printing were also revealed, and the formation and optimization of metal, polymer, and ceramic powders in powder‐based 3D printing equipment were explored. Throughout the last decade, powder‐based AM has gradually emerged in the fields of biomedical and aerospace, such as the construction of tissue scaffolds and the construction of aero‐engine parts, respectively. However, powder materials may have insufficient comprehensive performance due some limitations, as the control of mechanical characteristics and dimensional accuracy of powder moulded parts are still challenging during manufacturing processes. Therefore, exploring the mechanism/s of additive manufacturing of powder‐based materials, improving the mechanical properties of powder‐based AM products, and the possible directions for improving the usability of powder materials are the main focus of this paper.This article is protected by copyright. All rights reserved.

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Numerical simulation for electron beam selective melting PBF additive manufacturing of molybdenum

Cited by 6 publications

References 45 publications

Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

Recent Advances in CFD Simulations of Multiphase Flow Processes with Phase Change

Powder‐Based Additive Manufacturing: A Critical Review of Materials, Methods, Opportunities, and Challenges

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