3-Dimensional heat transfer modeling for laser powder-bed fusion additive manufacturing with volumetric heat sources based on varied thermal conductivity and absorptivity

Zhang, Zhidong; Huang, Yuze; Kasinathan, Adhitan Rani; Shahabad, Shahriar Imani; Ali, Usman; Mahmoodkhani, Yahya; Toyserkani, Ehsan

doi:10.1016/j.optlastec.2018.08.012

Cited by 184 publications

(66 citation statements)

References 36 publications

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“…As the convectional mechanisms of powder consolidation during selective laser melting are thermo-activated, there is a reason for obtaining a uniform temperature field T induced by the irradiation. It is known that if the thermal energy is released on an adiabatic plane bounding a uniform conducting half-space inside a circle of radius r0, with radial distribution, the steady temperature rise over this circle is uniform [76,77]: The knife-like formation of the molten pool, which is not as desirable for other technological laser applications as the precise laser cutting of thick sheets (with thickness more than 5 mm), laser scribing, and graving provoke multiple remelting of the material in the molten pool and interfusion with the previous layers due to its excess of energy on the treated surface. The excess of energy is related to the normal bell formed Gaussian distribution.…”

Section: Classification Of the Main Slm Parameters And The Way Of Lasmentioning

confidence: 99%

Section: Classification Of the Main Slm Parameters And The Way Of Lasmentioning

confidence: 99%

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Power Density Distribution for Laser Additive Manufacturing (SLM): Potential, Fundamentals and Advanced Applications

et al. 2018

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Problems with the laser additive manufacturing of metal parts related to its low efficiency are known to hamper its development and application. The method of selective laser melting of metallic powders can be improved by the installation of an additional laser beam modulator. This allows one to control the power density distribution optically in the laser beam, which can influence the character of heat and mass transfer in a molten pool during processing. The modulator contributes alternative modes of laser beam: Gaussian, flat top (top hat), and donut (bagel). The study of its influence includes a mathematical description and theoretical characterization of the modes, high-speed video monitoring and optical diagnostics, characterization of processing and the physical phenomena of selective laser melting, geometric characterization of single tracks, optical microscopy, and a discussion of the obtained dependences of the main selective laser melting (SLM) parameters and the field of its optimization. The single tracks were produced using the advanced technique of porosity lowering. The parameters of the obtained samples are presented in the form of 3D graphs. The further outlook and advanced applications are discussed.

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Section: Classification Of the Main Slm Parameters And The Way Of Lasmentioning

confidence: 99%

Section: Classification Of the Main Slm Parameters And The Way Of Lasmentioning

confidence: 99%

Power Density Distribution for Laser Additive Manufacturing (SLM): Potential, Fundamentals and Advanced Applications

et al. 2018

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“…Another way a new AM material can be introduced is by applying a numerical modeling approach with the objective of finding the appropriate printing parameters, as shown in [11][12][13][14][15]. However, due to a large number of variables, these models require significant time and computer resources to model a single laser track, let alone a complex part.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Laser Powder Bed Fusion Processing Using a Combination of Melt Pool Modeling and Design of Experiment Approaches: Density Control

Letenneur

Kreitcberg

Braïlovski

2019

JMMP

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A simplified analytical model of the laser powder bed fusion (LPBF) process was used to develop a novel density prediction approach that can be adapted for any given powder feedstock and LPBF system. First, calibration coupons were built using IN625, Ti64 and Fe powders and a specific LPBF system. These coupons were manufactured using the predetermined ranges of laser power, scanning speed, hatching space, and layer thickness, and their densities were measured using conventional material characterization techniques. Next, a simplified melt pool model was used to calculate the melt pool dimensions for the selected sets of printing parameters. Both sets of data were then combined to predict the density of printed parts. This approach was additionally validated using the literature data on AlSi10Mg and 316L alloys, thus demonstrating that it can reliably be used to optimize the laser powder bed metal fusion process.

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“…The latter can be indirectly controlled, using the first set of parameters, but it is harder to address. Several research groups are working to develop physical models to describe, and consequently control, the process, with some examples being described in [58][59][60][61][62][63][64][65][66][67][68][69]. Developed models also aim at defect forecasting and mitigation [70][71][72][73][74][75].…”

Section: Laser Powder Bed Fusion Working Principles and Process-relatmentioning

confidence: 99%

Laser Powder Bed Fusion of Stainless Steel Grades: A Review

Zitelli¹,

Folgarait²,

Schino

2019

Metals

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In this paper, the capability of laser powder bed fusion (L-PBF) systems to process stainless steel alloys is reviewed. Several classes of stainless steels are analyzed (i.e., austenitic, martensitic, precipitation hardening and duplex), showing the possibility of satisfactorily processing this class of materials and suggesting an enlargement of the list of alloys that can be manufactured, targeting different applications. In particular, it is reported that stainless steel alloys can be satisfactorily processed, and their mechanical performances allow them to be put into service. Porosities inside manufactured components are extremely low, and are comparable to conventionally processed materials. Mechanical performances are even higher than standard requirements. Micro surface roughness typical of the as-built material can act as a crack initiator, reducing the strength in both quasi-static and dynamic conditions.

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3-Dimensional heat transfer modeling for laser powder-bed fusion additive manufacturing with volumetric heat sources based on varied thermal conductivity and absorptivity

Cited by 184 publications

References 36 publications

Power Density Distribution for Laser Additive Manufacturing (SLM): Potential, Fundamentals and Advanced Applications

Power Density Distribution for Laser Additive Manufacturing (SLM): Potential, Fundamentals and Advanced Applications

Optimization of Laser Powder Bed Fusion Processing Using a Combination of Melt Pool Modeling and Design of Experiment Approaches: Density Control

Laser Powder Bed Fusion of Stainless Steel Grades: A Review

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