Transient dynamics and stability of keyhole at threshold in laser powder bed fusion regime investigated by finite element modeling
Source abstract
Abstract
A Finite element model is developed with a commercial code to investigate the keyhole dynamics and stability at keyhole threshold, a fusion regime characteristic to laser microwelding or to Laser Powder Bed Fusion. The model includes relevant physics to treat the hydrodynamic problems—surface tension, Marangoni stress, and recoil pressure—as well as a self-consistent ray-tracing algorithm to account for the “beam-trapping” effect. Implemented in both static and scanning laser configurations, the model successfully reproduces some key features that most recent x-ray images have exhibited. The dynamics of the liquid/gas interface is analyzed, in line with the distribution of the absorbed intensity as well as with the increase of the keyhole energy coupling. Based on these results, new elements are provided to discuss our current understanding of the keyhole formation and stability at threshold.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Laser Material Processing Techniques · Welding Techniques and Residual Stresses
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Safran Additive Manufacturing, A Technology Platform of Safran Tech 1 , Rue des Jeunes Bois, Chateaufort, 78114 Magny-Les-Hameaux, France
Laboratoire PIMM, Arts et Metiers Institute of Technology, CNRS, Cnam, HESAM University 2 , 151 boulevard de l’Hopital, 75013 Paris, France
MINES ParisTech, PSL Research University, CEMEF – Centre de Mise en Forme des Matériaux, CNRS UMR 7635, CS10207 rue Claude Daunesse 3 , 06904 Sophia Antipolis Cedex, France
References (45)
Show source-provided references
1. 2009
2. Scaling laws for the laser welding process in keyhole mode10.1016/j.jmatprotec.2018.09.027 ↗
3. Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging10.1126/science.aav4687 ↗
4. A novel “sandwich” method for observation of the keyhole in deep penetration laser welding10.1016/j.optlaseng.2007.08.010 ↗
5. Melt pool and keyhole behaviour analysis for deep penetration laser welding10.1088/0022-3727/43/44/445501 ↗
6. Laser welding and cutting: recent insights into fluid-dynamics mechanisms10.1117/12.513762 ↗
7. Understanding pore formation in laser beam welding10.1016/j.phpro.2011.03.031 ↗
8. Dynamics of keyhole and molten pool in laser welding10.2351/1.521858 ↗
9. Laser weld keyhole dynamics10.2351/1.521858 ↗
10. Bulk-explosion-induced metal spattering during laser processing10.1103/PhysRevX.9.021052 ↗
11. Ultrafast dynamics of laser-metal interactions in additive manufacturing alloys captured by in situ X-ray imaging10.1016/j.mtadv.2019.01.001 ↗
12. Keyhole dynamics and morphology visualized by in-situ X-ray imaging in laser melting of austenitic stainless steel10.1016/j.jmatprotec.2020.116673 ↗
13. In situ absorptivity measurements of metallic powders during laser powder-bed fusion additive manufacturing10.1016/j.apmt.2017.08.006 ↗
14. Time-resolved absorptance and melt pool dynamics during intense laser irradiation of a metal10.1103/PhysRevApplied.10.044061 ↗
15. Laser welding mode transition and influence of thermal focusing on mode transition10.1117/12.253136 ↗
16. Multiphysics modeling of pulsed laser welding10.2351/1.4983233 ↗
17. Effect of processing parameters during the laser beam melting of a nickel based alloy: Comparison between simulated and experimental melt pool shape10.1016/j.jmatprotec.2020.116897 ↗
18. Modelling of high-density laser-material interaction using fast level set method10.1088/0022-3727/34/3/320 ↗
19. Mechanism of keyhole formation and stability in stationary laser welding10.1088/0022-3727/35/13/320 ↗
20. An axi-symmetric thermo-hydraulic model to better understand spot laser welding10.3166/remn.17.795-806 ↗
21. Analysis of multi-phase interaction and its effects on keyhole dynamics with a multi-physics numerical model10.1088/0022-3727/47/34/345501 ↗
22. 3D transient multiphase model for keyhole, vapor plume, and weld pool dynamics in laser welding including the ambient pressure effect10.1016/j.optlaseng.2015.05.003 ↗
23. Multiphysics modelling of lack-of-fusion voids formation and evolution in IN718 made by multi-track/multi-layer L-PBF10.1016/j.ijheatmasstransfer.2019.05.003 ↗
24. Energy coupling mechanisms and scaling behavior associated with laser powder bed fusion additive manufacturing10.1002/adem.201900185 ↗
25. Effect of laser-matter interaction on molten pool flow and keyhole dynamics10.1103/PhysRevApplied.11.064054 ↗
26. Complete heat and fluid flow modeling of keyhole formation and collapse during spot laser welding10.2351/1.5062966 ↗
27. 2020
28. Numerical solution of phase-change problems10.1016/0017-9310(73)90202-0 ↗
29. 2003
30. Theoretical modeling of rapid surface vaporization with back pressure10.2514/3.61164 ↗
31. A fixed grid numerical modelling methodology for convection-diffusion mushy region phase-change problems10.1016/0017-9310(87)90317-6 ↗
32. COMSOL · 2020
33. 2002
34. Optical constants of transition metals: Ti, V, Cr, Mn, Fe, Co, Ni, and Pd10.1103/PhysRevB.9.5056 ↗
35. Dean · 1999
36. Determination of the thermophysical properties of liquid and solid Ti–6Al–4V alloy10.1007/s00339-016-9783-6 ↗
37. Temperature-dependent absorptance of painted aluminum, stainless steel 304, and titanium for 1.07μm and 10.6μm laser beams10.1016/j.optlaseng.2011.10.001 ↗
38. Energy-Coupling mechanisms revealed through simultaneous keyhole depth and absorptance measurements during laser-metal processing10.1103/PhysRevApplied.13.064070 ↗
39. Laser-induced plume investigated by finite element modelling and scaling of particle entrainment in laser powder bed fusion10.1088/1361-6463/ab5900 ↗
40. Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging10.1016/j.addma.2020.101362 ↗
41. The role of recoil pressure in energy balance during laser materials processing10.1088/0022-3727/30/18/008 ↗
42. Depth dependence and keyhole stability at threshold, for different laser welding regimes10.3390/app10041487 ↗
43. Corrections d’ouverture des corps noirs artificiels compte tenu des diffusions multiples internes
44. Physics of humping formation in laser powder bed fusion10.1016/j.ijheatmasstransfer.2019.119172 ↗
45. 2019