Finite Element Analysis of Interaction of Laser Beam with Material in Laser Metal Powder Bed Fusion Process

Fu, Guang; Zhang, Zhengwen; He, Allen; Mao, Zhiping; Zhang, Kaifei

doi:10.3390/ma11050765

Cited by 23 publications

(11 citation statements)

References 42 publications

(71 reference statements)

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“…Therefore, the availability of a physically adequate and fast mathematical model that allows the performance of numerical modeling will facilitate the development and optimization of technological parameters for the direct laser deposition process. A large number of papers describe the use of various numerical schemes of finite element analysis [ 9 , 10 , 11 ], analytical models [ 12 ], and even statistical models [ 13 ] for modeling thermal and hydrodynamic processes. However, in most of them, the case of cladding the bead on a thick and wide substrate is considered.…”

Section: Introductionmentioning

confidence: 99%

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

et al. 2021

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This article deals with the theoretical issues of the formation of a melt pool during the process of direct laser deposition. The shape and size of the pool depends on many parameters, such as the speed and power of the process, the optical and physical properties of the material, and the powder consumption. On the other hand, the influence of the physical processes occurring in the material on one another is significant: for instance, the heating of the powder and the substrate by laser radiation, or the formation of the free surface of the melt, taking into account the Marangoni effect. This paper proposes a model for determining the size of the melt bath, developed in a one-dimensional approximation of the boundary layer flow. The dimensions and profile of the surface and bottom of the melt pool are obtained by solving the problem of convective heat transfer. The influence of the residual temperature from the previous track, as well as the heat from the heated powder of the gas–powder jet, taking into account its spatial distribution, is considered. The simulation of the size and shape of the melt pool, as well as its free surface profile for different alloys, is performed with 316 L steel, Inconel 718 nickel alloy, and VT6 titanium alloy

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Section: Introductionmentioning

confidence: 99%

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

et al. 2021

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“…Hence, fully dense parts can be fabricated within a broad volumetric laser energy density range (i.e., laser scan speeds between 400-1400 mm/s, when a laser power of 500 W was employed). Simulation-based studies dealing with the laser-metal interaction during the LPBF process [44][45][46][47] revealed that the laser mainly irradiates the liquid melt pool and not the powder, except at a very high laser scan speeds. This could mean that the high optical absorption values obtained at room temperature for the surface-modified CuCr1 powder are no longer valid during the actual LPBF process.…”

Section: Lpbf Processing Behavior Part Production and Part Chemicalmentioning

confidence: 99%

Surface Modified Copper Alloy Powder for Reliable Laser-based Additive Manufacturing

Jadhav

Dhekne

Dadbakhsh

et al. 2020

Additive Manufacturing

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Owing to the high optical reflectivity of copper, silver, and gold in the infrared region, high laser power is required for laser-based additive manufacturing (L-AM). This increases the risk of damaging the laser optics due to sustained back-reflections and renders L-AM of reflective metals an unsustainable technology. To tackle this issue, a novel, industrially upscalable powder surface modification method is proposed and validated using a CuCr1 alloy. The surface of CuCr1 powder is modified by the outward diffusion of chromium in a nitrogen atmosphere, forming a rim around the powder particles. This doubled the optical absorption of the powder. Consequently, a mere 20% of the laser energy is required to process the surface-modified powder by laser powder bed fusion compared to the virgin CuCr1 powder. The fabricated parts demonstrate a very high thermal conductivity of 370 ± 15 W/(m•K) and tensile strength of 439 ± 19 MPa, after applying a suitable post-heat treatment.

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“…The absorption behavior of laser radiation from metallic powder materials in the PBF-LB/M process represents a decisive factor for the formation of a dense microstructure of the components. On the one hand, the absorption behavior depends on the exposure parameters and consequently, the duration of laser-material interaction as investigated by Fu et al [20] presented with finite element analysis. On the other hand, the material itself represents a significant influencing factor.…”

Section: Laser Absorption Of Metal Powdersmentioning

confidence: 99%

Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder

et al. 2021

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Research and development in the field of metal-based additive manufacturing are advancing steadily every year. In order to increase the efficiency of powder bed fusion of metals using a laser beam system (PBF LB/M), machine manufacturers have implemented extensive optimizations with regard to the laser systems and build volumes. However, the optimization of metallic powder materials using nanoparticle additives enables an additional improvement of the laser–material interaction. In this work, tool steel 1.2709 powder was coated with silicon carbide (SiC), few-layer graphene (FLG), and iron oxide black (IOB) on a nanometer scale. Subsequently, the feedstock material and the modified powder materials were analyzed concerning the reflectance of the laser radiation and processed by PBF-LB/M in a systematic and consistent procedure to evaluate the impact of the nano-additivation on the process efficiency and mechanical properties. As a result, an increased build rate is achieved, exhibiting a relative density of 99.9% for FLG/1.2709 due to a decreased reflectance of this modified powder material. Furthermore, FLG/1.2709 provides hardness values after precipitation hardening with only aging comparable to the original 1.2709 material and is higher than the SiC- and IOB-coated material. Additionally, the IOB coating tends to promote oxide-formation and lack-of-fusion defects.

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Finite Element Analysis of Interaction of Laser Beam with Material in Laser Metal Powder Bed Fusion Process

Cited by 23 publications

References 42 publications

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

Surface Modified Copper Alloy Powder for Reliable Laser-based Additive Manufacturing

Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder

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