Finite element analysis of thermal behavior of metal powder during selective laser melting

Huang, Yitao; Yang, Lechen; Du, Xiaoze; Yang, Yanping

doi:10.1016/j.ijthermalsci.2016.01.007

Cited by 156 publications

(64 citation statements)

References 20 publications

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“…Problems with localized nonhomogeneous material properties are of great interest in engineering [3,4,5,8,9,10,11,12,14,15,16,22,23,24,25,26,27]. In such problems, the varying physical properties between the different regions result in potentially large modeling differences.…”

Section: Introductionmentioning

confidence: 99%

“…In many instances, a material which comprises a relatively small portion of the domain may feature significantly more complex physics and, therefore, it may require a higher mesh resolution than in the remainder of the domain. Common examples of such problems with high industrial interest are thermal problems in additive manufacturing (where the nonlinear phase transformation phenomena occur only along a thin strip on the top of the domain) [3,10,11,12,14,15,16,22,23,24,25,26,27], or fluid flow problems through immersed membranes (where the flow properties change inside a subregion of the domain) [17,18,19,21]. A simple diagram of such a physical situation is shown in Fig.…”

Section: Introductionmentioning

confidence: 99%

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A Fat boundary-type method for localized nonhomogeneous material problems

Viguerie

Bertoluzza²,

Auricchio

2020

Computer Methods in Applied Mechanics and Engineering

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Problems with localized nonhomogeneous material properties arise frequently in many applications and are a well-known source of difficulty in numerical simulations. In certain applications (including additive manufacturing), the physics of the problem may be considerably more complicated in relatively small portions of the domain, requiring a significantly finer local mesh compared to elsewhere in the domain. This can make the use of a uniform mesh numerically unfeasible. While nonuniform meshes can be employed, they may be challenging to generate (particularly for regions with complex boundaries) and more difficult to precondition. The problem becomes even more prohibitive when the region requiring a finer-level mesh changes in time, requiring the introduction of refinement and derefinement techniques. To address the aforementioned challenges, we employ a technique related to the Fat boundary method [1,2,20] as a possible alternative. We analyze the proposed methodology from a mathematical point of view and validate our findings on two-dimensional numerical tests.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Fat boundary-type method for localized nonhomogeneous material problems

Viguerie

Bertoluzza²,

Auricchio

2020

Computer Methods in Applied Mechanics and Engineering

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“…While some studies have taken fluid dynamics effects in the melt pool into account (e.g., Marangoni convection in [33,44,45]), a significant number of works in the literature have neglected those effects to simplify the model (see for example [38][39][40]43]). The change in volume during melting of the powder [42,46,47] and layer built-up were modeled in some studies [37,41,48,49]. We refer the interested readers to review papers on numerical modeling and simulation of AM for more information [50][51][52].…”

Section: Melt Pool Modeling Through Fem Based Thermal Modelingmentioning

confidence: 99%

Multivariate Calibration and Experimental Validation of a 3D Finite Element Thermal Model for Laser Powder Bed Fusion Metal Additive Manufacturing

Mahmoudi

Tapia

Karayagiz

et al. 2018

Integr Mater Manuf Innov

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Metal additive manufacturing (AM) typically suffers from high degree of variability in the properties/performance of the fabricated parts, particularly due to the lack of understanding and control over the physical mechanisms that govern microstructure formation during fabrication. This paper directly addresses an important problem in AM: the determination of the thermal history of the deposited material. Any attempts to link process to microstructure in AM would need to consider the thermal history of the material. In-situ monitoring only provides partial information and simulations may be necessary to have a comprehensive understanding of the thermo-physical conditions to which the deposited material is subjected. We address this in the present work through linking thermal models to experiments via a computationally efficient surrogate modeling approach based on multivariate Gaussian processes (MVGPs). The MVGPs are then used to calibrate the free parameters of the multi-physics models against experiments, sidestepping the use of prohibitively expensive Monte Carlo-based calibration. This framework thus makes it possible to efficiently evaluate the impact of varying process parameter inputs on the characteristics of the melt pool during AM. We demonstrate the framework on the calibration of a thermal model for Laser-Powder Bed Fusion AM of Ti-6Al-4V against experiments carried out over a wide window in the process parameter space. While this work deals with problems related to AM, its applicability is wider as the proposed framework could potentially be used in many other ICME-based problems where it is essential to link expensive computational materials science models to available experimental data.

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“…The models produced by Huang et al [46], Li et al [47] and Kundakcioglu et al [48] are similar in nature to [45], but are more theoretically based, make fewer assumptions and heavily consider volume shrinkage and phase changes within the material. Coupled transient heat and mechanical analyses are used in these models.…”

Section: Temperature Distribution and Heat Transfer Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

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Abstract:A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of the literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging and design-of-experiments), support structure optimization and overhang feature design; approximately 143 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs and potential future research directions are discussed in-depth in light of the present review.

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Finite element analysis of thermal behavior of metal powder during selective laser melting

Cited by 156 publications

References 20 publications

A Fat boundary-type method for localized nonhomogeneous material problems

A Fat boundary-type method for localized nonhomogeneous material problems

Multivariate Calibration and Experimental Validation of a 3D Finite Element Thermal Model for Laser Powder Bed Fusion Metal Additive Manufacturing

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

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