Effect of Process Parameters on Melt Pool Geometry in Laser Powder Bed Fusion of Metals: A Numerical Investigation

Afrasiabi, Mohamadreza; Keller, D.; Lüthi, C.; Bambach, Markus; Wegener, Konrad

doi:10.1016/j.procir.2022.09.187

Cited by 12 publications

(2 citation statements)

References 31 publications

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“…1) Simulation domain is 2D 2) Heat source is volumetric and obeys the Beer-Lambert law 3) Laser moves with a constant speed 4) Flow of the molten material is incompressible 5) Gas phase and evaporation are not considered 6) All powder grains are spherical (i.e., circular in 2D) A brief description of the process simulator's main melt pool simulation and powder layer generation modules is presented next. A detailed description of the predictive capabilities and experimental validation of our SPH-based LPBF model for 2D and 3D single-track applications is available in [37], [39], [40].…”

Section: High-fidelity Multi-layer Lpbf Process Modelmentioning

confidence: 99%

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

Liao‐McPherson¹,

Balta²,

Wüest³

et al. 2022

2022 European Control Conference (ECC)

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Selective Laser Melting (SLM) is an additive manufacturing technology that builds three dimensional parts by melting layers of metal powder together with a laser that traces out a desired geometry. SLM is popular in industry, however the inherent melting and re-solidification of the metal during the process can, if left uncontrolled, cause excessive residual stress, porosity, and other defects in the final printed parts. This paper presents a control-oriented thermal model of a multilayer SLM process and proposes a structured model reduction methodology with an associated reduced order model based in-layer controller to track temperature references. Simulation studies demonstrate that the controller is able to prevent layerto-layer heat buildup and that good closed-loop performance is possible using relatively low-order models.

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Section: High-fidelity Multi-layer Lpbf Process Modelmentioning

confidence: 99%

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

Liao‐McPherson¹,

Balta²,

Wüest³

et al. 2022

2022 European Control Conference (ECC)

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“…The SPH method can be divided into the Weakly-Compressible SPH (WCSPH) and the Incompressible SPH (ISPH) method. In the current state of the art, both methods demonstrate promising results in the application to laser material processing as shown in [1,2,3].…”

Section: Introductionmentioning

confidence: 99%

Comparison of Incompressible and Weakly-Compressible SPH for the Simulation of Laser Beam Welding

Sollich,

Eberhard

2023

VIII International Conference on Particle-Based Methods

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The process of laser beam welding is simulated using the Weakly-Compressible Smoothed Particle Hydrodynamics (WCSPH) and the Incompressible SPH (ISPH) methods. The presented models consider significant physical effects such as heat conduction, temperature-dependent surface tension with wetting, the phase transitions melting and solidification, and an evaporation-induced recoil pressure. Here, particular emphasis is placed on the modeling differences between the WCSPH and ISPH methods. Then, both methods are evaluated in terms of their accuracy and performance in the simulation of deep penetration laser beam welding with oscillating laser power.

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Particle-based modelling of laser powder bed fusion of metals with emphasis on the melting mode transition

Bierwisch,

Dietemann,

Najuch

2024

Granular Matter

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The laser-beam powder bed fusion process for metals, commonly abbreviated as PBF-LB/M, is a widely used process for the additive manufacturing of parts. Numerical simulations are useful to identify optimal process parameters for different materials and to obtain detailed insights into process dynamics. The present work uses a single-phase incompressible Smoothed Particle Hydrodynamics (SPH) scheme to model PBF-LB/M which was found to reduce the required computational time and significantly stabilize the partially violent flow in the melt pool in comparison to a weakly compressible SPH approach. The laser-material interaction is realistically modelled by means of a ray tracing method. An approach to model the effective thermal coductivity of the powder bed is proposed. Excellent agreement between the simulation results and experimental X-ray analyses of the transition from conduction melting mode to keyhole mode including geometric properties of the vapor depression zone was found. These results prove the usability of SPH as a high precision simulation tool for PBF-LB/M. Graphic abstract

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Effect of Process Parameters on Melt Pool Geometry in Laser Powder Bed Fusion of Metals: A Numerical Investigation

Cited by 12 publications

References 31 publications

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

In-layer Thermal Control of a Multi-layer Selective Laser Melting Process

Comparison of Incompressible and Weakly-Compressible SPH for the Simulation of Laser Beam Welding

Particle-based modelling of laser powder bed fusion of metals with emphasis on the melting mode transition

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