A thermo-metallurgical-mechanical model for selective laser melting of Ti6Al4V

Tan, Pengfei; Shen, Fei; Li, Biao; Zhou, Kun

doi:10.1016/j.matdes.2019.107642

Cited by 108 publications

(41 citation statements)

References 40 publications

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“…Powder–liquid–solid transition comprises melting, vaporization, solidification, shrinkage and cooling phenomena. Stress fields have been assessed via the elasto-plastic constitutive relationship including thermal strain and volumetric change strain [ 127 ].…”

Section: Numerical Simulation Of Slmmentioning

confidence: 99%

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

et al. 2020

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Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.

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Section: Numerical Simulation Of Slmmentioning

confidence: 99%

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

et al. 2020

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“…Layer deposition is simulated by activating the elements of the actual powder bed to be scanned while materials properties change from powder to consolidate material when the melting point is reached at elements nodes. Tan et al [110] developed a layer-scale thermo-metallurgical-mechanical model of Ti6Al4V selective laser melting process. The temperature history at each node is first calculated by simulating the laser scanning over the powder bed.…”

Section: Residual Stress and Distortionsmentioning

confidence: 99%

“…where β and α' are β-phase and martensitic phase, respectively, B s and B f (1253 K) are the start and finish temperatures of the α to β transformation, Ms (923 K) and Mf are the start and finish temperatures of the β to α' transformation, f'β is the initial volume fraction of the β phase during martensitic transformation. Finally, the effect of specific volume variation induced by solid-state phase transformation is calculated and applied using an equivalent thermal expansion coefficient, which detailed expression is given in [110]:…”

Section: Residual Stress and Distortionsmentioning

confidence: 99%

“…Effect of solid-state phase transformation on residual stress [110]  The higher the diffusivity the lower the residual stress  The higher the thermal conductivity the lower the residual stress  The lower the yield stress the lower the residual stress [143] Figure 24: Summary of most important outcomes about the influence of process parameters and material properties on residual stress induced by PBFP.…”

Section: Beam Variablesmentioning

confidence: 99%

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Understanding powder bed fusion additive manufacturing phenomena via numerical simulation

Ferro

Berto

Romanin

2020

Frattura Ed Integrità Strutturale

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The increasing interest in additively manufactured metallic parts from industry has issued a formidable challenge to the academic and scientific world that is asked to design new alloys, optimize process parameters and geometry as well as guarantee the reliability of a new generation of loadbearing components. Unfortunately, understanding the interaction between different phenomena associated to metal-additive manufacturing processes is a very difficult task. In this scenario, numerical modelling emerges as a valid technique to face problems related to the influence of process parameters on metallurgical and mechanical properties of additively manufactured components. This contribution is aimed at summarizing the most important outcomes about metal-additive manufacturing process obtained via numerical simulation with particular reference to powder bed fusion techniques. The fundamentals of additive manufacturing numerical simulation will be also explained in detail. Thermal, metallurgical as well as mechanical aspects are covered.

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“…In [17], Li et al enhanced their proposed approach by including the residual stress field analysis. A similar numerical approach was presented by Tan et al [18] based on a model addressing thermal, metallurgical, and mechanical effects for selective laser melting of titanium alloy. The aforementioned numerical models, although they consider all physical phenomena and elucidate the physical processes involved in the melt pool formation, are computationally intensive and cannot be used for real-time process control and optimization.…”

Section: Introductionmentioning

confidence: 99%

Phase Change with Density Variation and Cylindrical Symmetry: Application to Selective Laser Melting

Fyrillas

Ioannou

Papadakis

et al. 2019

JMMP

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In this paper we introduce an analytical approach for predicting the melting radius during powder melting in selective laser melting (SLM) with minimum computation duration. The purpose of this work is to evaluate the suggested analytical expression in determining the melt pool geometry for SLM processes, by considering heat transfer and phase change effects with density variation and cylindrical symmetry. This allows for rendering first findings of the melt pool numerical prediction during SLM using a quasi-real-time calculation, which will contribute significantly in the process design and control, especially when applying novel powders. We consider the heat transfer problem associated with a heat source of power Q' (W/m) per unit length, activated along the span of a semi-infinite fusible material. As soon as the line heat source is activated, melting commences along the line of the heat source and propagates cylindrically outwards. The temperature field is also cylindrically symmetric. At small times (i.e., neglecting gravity and Marangoni effects), when the density of the solid material is less than that of the molten material (i.e., in the case of metallic powders), an annulus is created of which the outer interface separates the molten material from the solid. In this work we include the effect of convection on the melting process, which is shown to be relatively important. We also justify that the assumption of constant but different properties between the two material phases (liquid and solid) does not introduce significant errors in the calculations. A more important result; however, is that, if we assume constant energy input per unit length, there is an optimum power of the heat source that would result to a maximum amount of molten material when the heat source is deactivated. The model described above can be suitably applied in the case of selective laser melting (SLM) when one considers the heat energy transferred to the metallic powder bed during scanning. Using a characteristic time and length for the process, we can model the energy transfer by the laser as a heat source per unit length. The model was applied in a set of five experimental data, and it was demonstrated that it has the potential to quantitatively describe the SLM process.

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A thermo-metallurgical-mechanical model for selective laser melting of Ti6Al4V

Cited by 108 publications

References 40 publications

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

Understanding powder bed fusion additive manufacturing phenomena via numerical simulation

Phase Change with Density Variation and Cylindrical Symmetry: Application to Selective Laser Melting

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