Thermal behavior in single track during selective laser melting of AlSi10Mg powder
Source abstract
Abstract
A three-dimensional model was developed to simulate the radiation heat transfer in the AlSi10Mg packed bed. The volume of fluid method (VOF) was used to capture the free surface during selective laser melting (SLM). A randomly packed powder bed was obtained using discrete element method (DEM) in Particle Flow Code (PFC). The proposed model has demonstrated a high potential to simulate the selective laser melting process (SLM) with high accuracy. In this paper, the effect of the laser scanning speed and laser power on the thermodynamic behavior of the molten pool was investigated numerically. The results show that the temperature gradient and the resultant surface tension gradient between the center and the edge of the molten pool increase with decreasing the scanning speed or increasing the laser power, thereby intensifying the Marangoni flow and attendant turbulence within the molten pool. However, at a relatively high scanning speed, a significant instability may be generated in the molten pool. The perturbation and instability in the molten pool during SLM may result in an irregular shaped track.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Welding Techniques and Residual Stresses
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (48)
Show source-provided references
1. D. Gu, W. Meiners, K. Wissenbach et al., Laser additive manufacturing of metallic components: materials, processes and mechanisms. Int. Mater. Rev. 57(3), 133–164 (2012)10.1179/1743280411Y.0000000014 ↗
2. E.O. Olakanmi, R.F. Cochrane, K.W. Dalgarno, A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: processing, microstructure, and properties. Prog. Mater Sci. 74, 401–477 (2015)10.1016/j.pmatsci.2015.03.002 ↗
3. C. Körner, E. Attar, P. Heinl, Mesoscopic simulation of selective beam melting processes. J. Mater. Process. Technol. 211(6), 978–987 (2011)10.1016/j.jmatprotec.2010.12.016 ↗
4. Standard ASTM, F2792. 2012. Standard Terminology for Additive Manufacturing Technologies (ASTM International, West Conshohocken, 2012), http://www.astm.Org . doi: 10.1520/F2792-1210.1520/F2792-12 ↗
5. F. Abe, K. Osakada, M. Shiomi et al., The manufacturing of hard tools from metallic powders by selective laser melting. J. Mater. Process. Technol. 111(1), 210–213 (2011)
6. J.F. Li, L. Li, F.H. Stott, Comparison of volumetric and surface heating sources in the modeling of laser melting of ceramic materials. Int. J. Heat Mass Transf. 47(6), 1159–1174 (2004)
7. D. Gu, Z. Wang, Y. Shen et al., In-situ TiC particle reinforced Ti–Al matrix composites: powder preparation by mechanical alloying and selective laser melting behavior. Appl. Surf. Sci. 255(22), 9230–9240 (2009)10.1016/j.apsusc.2009.07.008 ↗
8. T.B. Sercombe, X. Li, Selective laser melting of aluminium and aluminium metal matrix composites: review. Mater. Technol. Advanced Performance Materials No. 1753555715Y-0000000078, (2015)10.1179/1753555715Y.0000000078 ↗
9. E. Louvis, P. Fox, C.J. Sutcliffe, Selective laser melting of aluminium components. J. Mater. Process. Technol. 211(2), 275–284 (2011)10.1016/j.jmatprotec.2010.09.019 ↗
10. X.P. Li, X.J. Wang, M. Saunders et al., A selective laser melting and solution heat treatment refined Al–12Si alloy with a controllable ultrafine eutectic microstructure and 25% tensile ductility. Acta Mater. 95, 74–82 (2015)10.1016/j.actamat.2015.05.017 ↗
11. E.O. Olakanmi, R.F. Cochrane, K.W. Dalgarno, Densification mechanism and microstructural evolution in selective laser sintering of Al–12Si powders. J. Mater. Process. Technol. 211(1), 113–121 (2011)10.1016/j.jmatprotec.2010.09.003 ↗
12. F. Calignano, D. Manfredi, E.P. Ambrosio et al., Influence of process parameters on surface roughness of aluminum parts produced by DMLS. Int. J. Adv. Manuf. Technol. 67(9–12), 2743–2751 (2013)10.1007/s00170-012-4688-9 ↗
13. D. Manfredi, F. Calignano, M. Krishnan et al., From powders to dense metal parts: characterization of a commercial AlSiMg alloy processed through direct metal laser sintering. Materials 6(3), 856–869 (2013)10.3390/ma6030856 ↗
14. K. Bartkowiak, S. Ullrich, T. Frick et al., New developments of laser processing aluminium alloys via additive manufacturing technique. Phys. Procedia 12, 393–401 (2011)10.1016/j.phpro.2011.03.050 ↗
15. L. Thijs, K. Kempen, J.P. Kruth et al., Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder. Acta Mater. 61(5), 1809–1819 (2013)10.1016/j.actamat.2012.11.052 ↗
16. X.J. Wang, L.C. Zhang, M.H. Fang et al., The effect of atmosphere on the structure and properties of a selective laser melted Al–12Si alloy. Mater. Sci. Eng. A 597, 370–375 (2014)10.1016/j.msea.2014.01.012 ↗
17. R. Chou, J. Milligan, M. Paliwal et al., Additive manufacturing of Al − 12Si alloy via pulsed selective laser melting. JOM 67(3), 590–596 (2015)10.1007/s11837-014-1272-9 ↗
18. E.O. Olakanmi, Selective laser sintering/melting (SLS/SLM) of pure Al, Al–Mg, and Al–Si powders: effect of processing conditions and powder properties. J. Mater. Process. Technol. 213(8), 1387–1405 (2013)10.1016/j.jmatprotec.2013.03.009 ↗
19. Y.M. Zhang, Z.H. Shen, X.W. Ni, Modeling and simulation on long pulse laser drilling processing. Int. J. Heat Mass Transf. 73, 429–437 (2014)10.1016/j.ijheatmasstransfer.2014.02.037 ↗
20. M. Shiomi, A. Yoshidome, F. Abe et al., Finite element analysis of melting and solidifying processes in laser rapid prototyping of metallic powders. Int. J. Mach. Tools Manuf 39(2), 237–252 (1999)10.1016/S0890-6955(98)00036-4 ↗
21. M. Matsumoto, M. Shiomi, K. Osakada et al., Finite element analysis of single layer forming on metallic powder bed in rapid prototyping by selective laser processing. Int. J. Mach. Tools Manuf 42(1), 61–67 (2002)10.1016/S0890-6955(01)00093-1 ↗
22. S. Kolossov, E. Boillat, R. Glardon et al., 3D FE simulation for temperature evolution in the selective laser sintering process. Int. J. Mach. Tools Manuf. 44(2), 117–123 (2004)10.1016/j.ijmachtools.2003.10.019 ↗
23. B. Xiao, Y. Zhang, Marangoni and buoyancy effects on direct metal laser sintering with a moving laser beam. Numer. Heat Transf. Part A Appl. 51(8), 715–733 (2007)10.1080/10407780600968593 ↗
24. D. Dai, D. Gu, Tailoring surface quality through mass and momentum transfer modeling using a volume of fluid method in selective laser melting of TiC/AlSi10Mg powder. Int. J. Mach. Tools Manuf. 88, 95–107 (2015)10.1016/j.ijmachtools.2014.09.010 ↗
25. D. Dai, D. Gu, Influence of thermodynamics within molten pool on migration and distribution state of reinforcement during selective laser melting of AlN/AlSi10Mg composites. Int. J. Mach. Tools Manuf. 100, 14–24 (2016)10.1016/j.ijmachtools.2015.10.004 ↗
26. L.E. Loh, C.K. Chua, W.Y. Yeong et al., Numerical investigation and an effective modelling on the Selective Laser Melting (SLM) process with aluminium alloy 6061. Int. J. Heat Mass Transf. 80, 288–300 (2015)10.1016/j.ijheatmasstransfer.2014.09.014 ↗
27. N.K. Tolochko, M.K. Arshinov, A.V. Gusarov et al., Mechanisms of selective laser sintering and heat transfer in Ti powder. Rapid Prototyp. J. 9(5), 314–326 (2003)10.1108/13552540310502211 ↗
28. S.A. Khairallah, A. Anderson, Mesoscopic simulation model of selective laser melting of stainless steel powder. J. Mater. Process. Technol. 214(11), 2627–2636 (2014)10.1016/j.jmatprotec.2014.06.001 ↗
29. S.A. Khairallah, A.T. Anderson, A. Rubenchik et al., Laser powder-bed fusion additive manufacturing: physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones. Acta Mater. 108, 36–45 (2016)10.1016/j.actamat.2016.02.014 ↗
30. A. Klassen, T. Scharowsky, C. Körner, Evaporation model for beam based additive manufacturing using free surface lattice Boltzmann methods. J. Phys. D Appl. Phys. 47(27), 275303 (2014)10.1088/0022-3727/47/27/275303 ↗
31. J.N. Roux, Geometric origin of mechanical properties of granular materials. Phys. Rev. E 61(6), 6802 (2000)10.1103/PhysRevE.61.6802 ↗
32. G. Rong, G. Liu, D. Hou et al., Effect of particle shape on mechanical behaviors of rocks: a numerical study using clumped particle model. Sci. World J. NO. 589215, (2013)10.1155/2013/589215 ↗
33. P. Yuan, D. Gu, Molten pool behaviour and its physical mechanism during selective laser melting of TiC/AlSi10Mg nanocomposites: simulation and experiments. J. Phys. D Appl. Phys. 48(3), 035303 (2015)10.1088/0022-3727/48/3/035303 ↗
34. Y. Li, D. Gu, Parametric analysis of thermal behavior during selective laser melting additive manufacturing of aluminum alloy powder. Mater. Design 63, 856–867 (2014)10.1016/j.matdes.2014.07.006 ↗
35. L.K. Ang, Y.Y. Lau, R.M. Gilgenbach et al., Analysis of laser absorption on a rough metal surface. Appl. Phys. Lett. 70(6), 696–698 (1997)10.1063/1.118242 ↗
36. S.C. Stacy, X. Zhang, M. Pantoya et al., The effects of density on thermal conductivity and absorption coefficient for consolidated aluminum nanoparticles. Int. J. Heat Mass Transf. 73, 595–599 (2014)10.1016/j.ijheatmasstransfer.2014.02.050 ↗
37. C. Weingarten, D. Buchbinder, N. Pirch et al., Formation and reduction of hydrogen porosity during selective laser melting of AlSi10Mg. J. Mater. Process. Technol. 221, 112–120 (2015)10.1016/j.jmatprotec.2015.02.013 ↗
38. C.W. Hirt, B.D. Nichols, Volume of fluid (VOF) method for the dynamics of free boundaries. J. Comput. Phys. 39, 201–225 (1981)10.1016/0021-9991(81)90145-5 ↗
39. M.H. Cho, Y.C. Lim, D.F. Farson, Simulation of weld pool dynamics in the stationary pulsed gas metal arc welding process and final weld shape. Weld. J. N. Y. 85(12), 271 (2006)
40. Y.S. Lee, W. Zhang, Mesoscopic simulation of heat transfer and fluid flow in laser powder bed additive manufacturing, in International Solid Free Form Fabrication Symposium (Austin, 2015), pp. 1154–1165
41. Y.S. Lee, W. Zhang, Modeling of heat transfer, fluid flow and solidification microstructure of nickel-base superalloy fabricated by laser powder bed fusion. Addit. Manuf. 12, 178–188 (2016)10.1016/j.addma.2016.05.003 ↗
42. V.R. Voller, C. Prakash, A fixed grid numerical modeling methodology for convection-diffusion mushy region phase-change problems. Int. J. Heat Mass Transf. 30(8), 1709–1719 (1987)10.1016/0017-9310(87)90317-6 ↗
43. J.H. Cho, S.J. Na, Implementation of real-time multiple reflection and Fresnel absorption of laser beam in keyhole. J. Phys. D Appl. Phys. 39, 5372–5378 (2006)10.1088/0022-3727/39/24/039 ↗
44. L. Dou, Z.F. Yuan, J.Q. Li et al., Surface tension of molten Al–Si alloy at temperatures ranging from 923 to 1123 K. Chin. Sci. Bull. 53(17), 2593–2598 (2008)10.1007/s11434-008-0372-8 ↗
45. P. Wei, Z. Wei, G. Zhao et al., Flow characteristic of in-flight particles in supersonic plasma spraying process, Heat Mass Transf. 1–15 (2015)10.1007/s00231-015-1693-1 ↗
46. V.V. Pujar, R.P. Jensen, N.P. Padture, Densification of liquid-phase-sintered silicon carbide. J. Mater. Sci. Lett. 19(11), 1011–1014 (2000)10.1023/A:1006753213286 ↗
47. I.C. Hawkes, M. Lamb, W.M. Steen et al., Surface topography and fluid flow in laser surface melting. Proc. CISFFEL 1, 125–132 (1983)
48. C. Körner, A. Bauereiß, E. Attar, Fundamental consolidation mechanisms during selective beam melting of powders. Model. Simul. Mater. Sci. Eng. 21(8), 085011 (2013)10.1088/0965-0393/21/8/085011 ↗