Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites

Abolhasani, Daniyal; Seyedkashi, S. M. H.; Kang, Ning; Kim, Yang Jin; Woo, Young Yun; Moon, Young Hoon

doi:10.3390/met9080876

Cited by 31 publications

(10 citation statements)

References 39 publications

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“…The main additive manufacturing technologies suitable for metals are selective laser melting (SLM), selective electron beam melting (SEBM), laser powder deposition, binder jet additive manufacturing (BJAM), and wire arc additive manufacturing (WAAM) [39][40][41][42][43][44][45][46][47][48][49]. So far, AM technologies have been successfully applied to stainless steels [50][51][52][53][54], Ni alloys [55,56], Ti alloys [57,58], refractory metals [59,60], Al alloys [61,62], etc. For tungsten carbide-cobalt, it still remains very challenging to use AM due to its very high melting temperature.…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing of WC-Co hardmetals: a review

Yang

Zhang

Wang

et al. 2020

Int J Adv Manuf Technol

105

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WC-Co hardmetals are widely used in wear-resistant parts, cutting tools, molds, and mining parts, owing to the combination of high hardness and high toughness. WC-Co hardmetal parts are usually produced by casting and powder metallurgy, which cannot manufacture parts with complex geometries and often require post-processing such as machining. Additive manufacturing (AM) technologies are able to fabricate parts with high geometric complexity and reduce post-processing. Therefore, additive manufacturing of WC-Co hardmetals has been widely studied in recent years. In this article, the current status of additive manufacturing of WC-Co hardmetals is reviewed. The advantages and disadvantages of different AM processes used for producing WC-Co parts, including selective laser melting (SLM), selective electron beam melting (SEBM), binder jet additive manufacturing (BJAM), 3D gel-printing (3DGP), and fused filament fabrication (FFF) are discussed. The studies on microstructures, defects, and mechanical properties of WC-Co parts manufactured by different AM processes are reviewed. Finally, the remaining challenges in additive manufacturing of WC-Co hardmetals are pointed out and suggestions on future research are discussed.

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Section: Introductionmentioning

confidence: 99%

Additive manufacturing of WC-Co hardmetals: a review

Yang

Zhang

Wang

et al. 2020

Int J Adv Manuf Technol

105

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“…where h is the heat transfer coefficient (20 W/m 2 K [14]), T0 is the surrounding temperature (300 K), T is the surface temperature during the laser heating processing, ε is the emissivity (0.8 and 0.32 for the heated surfaces with graphite coating and uncoated domains, respectively), and ϭ is the Stefan-Boltzmann constant (5.6703 × 10 −8 W/m 2 K 4 ). The temperature dependences of the other parameters were obtained from the material supplier and literature [15].…”

Section: Determination Of Strains and Temperaturesmentioning

confidence: 99%

Section: Etermination Of Strains and Temperaturesmentioning

confidence: 99%

Effects of Laser Beam Parameters on Bendability and Microstructure of Stainless Steel in Three-Dimensional Laser Forming

et al. 2019

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In this study, the effects of beam diameter and hatch spacing between the scanning paths on the bendability and microstructural behavior of an AISI 316 stainless-steel sheet in three-dimensional laser forming were investigated. The strain on the heating lines and that between the scanning tracks were numerically investigated to elucidate the effects of process parameters. The strain on heating lines and that between scanning tracks were numerically investigated. The increase in hatch spacing caused a larger amount of counter bending to be retained in the unaffected areas between the tracks through a process dominated by a temperature gradient mechanism (TGM), and also caused a lower deformation. The formation of small equiaxed dendrite grains instead of coarse and inhomogeneous austenite grains occurred during the process at a larger beam diameter and smaller hatch spacing, which increased the bendability of the material, owing to the decrease in anisotropy in the microstructure. Moreover, the increase in the grain size of the reheated overlap region of the deformed sample led to a higher bendability. Under these conditions, the microhardness was also increased owing to the grain boundary strengthening effect.

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“…On the modeling front for LPBF, literature focusing on the modeling of the rich multiphysics aspects of the process has been extensively published. Abolhasani et al [16] studied the effect of reinforced materials on the cooling rates and meltpool behavior of AlSI 304 stainless steel using finite element method simulations. Ansari et al [17] developed a 3D finite element method based thermal model using a volumetric Gaussian laser heat source to model the thermal profile and meltpool 2 size in selective laser melting process.…”

Section: Introductionmentioning

confidence: 99%

A Numerical Investigation of Dimensionless Numbers Characterizing Meltpool Morphology of the Laser Powder Bed Fusion Process

Bhagat¹,

Rudraraju²

2022

Preprint

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Microstructure evolution in metal additive manufacturing (AM) is a complex multi-physics and multi-scale problem. Understanding the impact of AM process conditions on microstructure evolution and the resulting mechanical properties of the printed part is an area of active research. In this context, high-fidelity numerical modeling of the AM process at various relevant length-scales has been finding favor. At the meltpool scale, the thermo-fluidic governing equations have been extensively modeled to understand the meltpool conditions and thermal gradients. In many phenomena governed by partial differential equations, dimensional analysis and identification of important dimensionless numbers can provide significant insights into the process dynamics. Hence, the use of dimensionless numbers to understand the complex multiphysics interactions active during metal AM is also gaining traction. In this context, we present a novel strategy using dimensional analysis and the least-squares regression approach, in conjunction with physics-based insights, to investigate the thermo-fluidic governing equations of the Laser Powder Bed Fusion AM process. Through this approach, we identify important dimensionless quantities influencing meltpool morphology. The governing equations are solved using the Finite Element Method, and the model predictions are validated by comparing with experimentally estimated cooling rates, and with numerical results from the literature. We then present our dimensional analysis and define an important dimensionless quantity - interpreted as a measure of heat absorbed by the powdered material and the resulting meltpool. We then use this dimensionless measure of heat absorbed, along with classical dimensionless quantities relevant to the thermo-fluidic governing equations, to investigate advective transport in the meltpool for different metal alloys. This understanding helps us characterize the meltpool aspect ratio and volume in terms of the Marangoni, and Stefan numbers. Further, we study the variations of thermal gradients and the solidification cooling rate using this framework and examine the effect of the Peclet number on the microstructure of the solidified meltpool region.

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Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites

Cited by 31 publications

References 39 publications

Additive manufacturing of WC-Co hardmetals: a review

Additive manufacturing of WC-Co hardmetals: a review

Effects of Laser Beam Parameters on Bendability and Microstructure of Stainless Steel in Three-Dimensional Laser Forming

A Numerical Investigation of Dimensionless Numbers Characterizing Meltpool Morphology of the Laser Powder Bed Fusion Process

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