Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 32759
FEM Simulations to Study the Effects of Laser Power and Scan Speed on Molten Pool Size in Additive Manufacturing

Authors: Yee-Ting Lee, Jyun-Rong Zhuang, Wen-Hsin Hsieh, An-Shik Yang

Abstract:

Additive manufacturing (AM) is increasingly crucial in biomedical and aerospace industries. As a recently developed AM technique, selective laser melting (SLM) has become a commercial method for various manufacturing processes. However, the molten pool configuration during SLM of metal powders is a decisive issue for the product quality. It is very important to investigate the heat transfer characteristics during the laser heating process. In this work, the finite element method (FEM) software ANSYS® (work bench module 16.0) was used to predict the unsteady temperature distribution for resolving molten pool dimensions with consideration of temperature-dependent thermal physical properties of TiAl6V4 at different laser powers and scanning speeds. The simulated results of the temperature distributions illustrated that the ratio of laser power to scanning speed can greatly influence the size of molten pool of titanium alloy powder for SLM development.

Keywords: Additive manufacturing, finite element method, molten pool dimensions, selective laser melting.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1131063

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1591

References:


[1] I. Yadroitsev, I. Yadroitsava, P. Bertrand, and I. Smurov, “Factor analysis of selective laser melting process parameters and geometrical characteristics of synthesized single tracks”, Rapid Prototyp. J., vol. 18, pp. 201–208, 2012.
[2] A. Hussein, L. Hao, C. Yan, and R. Everson, “Finite element simulation of the temperature and stress fields in single layers built without-support in selective laser melting”, Mater. Des., vol. 52, pp. 638–647, 2013.
[3] I. Yadroitsev, P. Krakhmalev, and I. Yadroitsava, “Selective laser melting of Ti6Al4V alloy for biomedical applications: Temperature monitoring and microstructural evolution”, J. Alloy. Compd., vol. 583, pp. 404–409, 2014.
[4] D. D. Gu, Y. C. Hagedorn, W. Meiners, G. Meng, R. J. S. Batista, K. Wissenbach, and R. Poprawe, “Densification behavior, microstructure evolution, and wear performance of selective laser melting processed commercially pure titanium”, Acta Mater., vol. 60, pp. 3849–3860, 2012.
[5] K. Dai, and L. Shaw, “Finite element analysis of the effect of volume shrinkage during laser densification”, Acta Mater., vol. 53, pp. 4743–4754, 2005.
[6] D. D. Gu, and Y. Shen, “Balling phenomena in direct laser sintering of stainless steel powder: metallurgical mechanisms and control methods”, Mater. Des., vol. 30, pp. 2903–2910, 2009.
[7] Y. W. Zhang, A. Faghri, C. W. Buckley, and T. L. Bergman, “Three-dimensional sintering of two-component metal powders with stationary and moving laser beams”, J Heat Transfer, vol. 122, pp. 150–158, 2000.
[8] I. A. Roberts, C. J. Wang, R. Esterlein, M. Stanford, and D.J. Mynors, “A three-dimensional finite element analysis of the temperature field during laser melting of metal powders in additive layer manufacturing”, Int. J. Mach. Tools Manuf., vol. 49, pp. 916–923, 2009.
[9] A. V. Gusarov, and I. Smurov, “Modeling the interaction of laser radiation with powder bed at selective laser melting”, Phys Procedia, vol. 5, pp. 381–394, 2010.
[10] H. S. Carslaw, and J.C. Jaeger, “Conduction of Heat in Solids”, 2nd ed, Oxford University Press, Oxford, 1986.
[11] G. Germain, F. Morel, and J. L. Lebrun, “A Morel, Machinability and surface integrity for a bearing steel and a titanium alloy in laser assisted machining”, Laser Eng., vol. 17, pp. 329–344, 2007.
[12] J. Yin, H.H. Zhu, L. D. Ke, W. J. Lei, C. Dai, and D. L. Zuo, “Simulation of temperature distribution in single metallic powder layer for laser micro-sintering”, Comput. Mater. Sci., vol. 53, pp. 333–339, 2012.
[13] Y. Huang, L. J. Yang, X. Z. Du, and Y. P. Yang, “Finite element analysis of thermal behavior of metal powder during selective laser melting”, Int. J. Therm. Sci., vol. 104, pp. 146-157, 2016.
[14] M. Rombouts, L. Froyen, A. V. Gusarov, E. H. Bentefour, and C. Glorieux, “Light extinction in metallic powder beds: correlation with powder structure”, J Appl. Phys., vol. 98, 2005.
[15] S.S. Sih, and J.W. Barlow, “The prediction of the emissivity and thermal conductivity of powder beds”, Part. sci. technol., vol. 22, pp. 427–440, 2004.
[16] V. Fallah, M. Alimardani, S. Corbin, and A. Khajepour, “Temporal development of melt-pool morphology and clad geometry in laser powder deposition”, Comput. Mater. Sci., vol. 50, pp. 2124–2134, 2011.