Modeling and numerical studies of selective laser melting: Multiphase flow, solidification and heat transfer

He, Qiwei; Xia, Huanxiong; Liu, Jianhua; Ao, Xiaohui; Lin, Shengxiang

doi:10.1016/j.matdes.2020.109115

Cited by 43 publications

(18 citation statements)

References 38 publications

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“…Three-dimensional printed parts show different properties depending on other AM techniques [2]. Fused deposition modeling (FDM), selective laser melting (SLM), multi-jet modeling (MJM), laminated object manufacturing (LOM), and stereolithography (SLA) and selective laser sintering (SLS) are various additive manufacturing (AM) methods [3][4][5][6][7][8]. Additive manufacturing provides the ability to produce complex geometries that are difficult to produce by conventional methods without complex tooling.…”

Section: Introductionmentioning

confidence: 99%

Mathematical Modeling and Optimization of Fused Filament Fabrication (FFF) Process Parameters for Shape Deviation Control of Polyamide 6 Using Taguchi Method

et al. 2021

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Fused filament fabrication (FFF) is a layer-by-layer additive manufacturing (AM) process for producing parts. For industries to gain a competitive advantage, reducing product development cycle time is a basic goal. As a result, industries’ attention has turned away from traditional product development processes toward rapid prototyping techniques. Because different process parameters employed in this method significantly impact the quality of FFF manufactured parts, it is essential to optimize FFF process parameters to enhance component quality. The paper presents optimization of fused filament fabrication process parameters to improve the shape deviation such as cylindricity and circularity of 3D printed parts with the Taguchi optimization method. The effect of thickness, infill pattern, number of walls, and layer height was investigated as variable parameters for experiments on cylindricity and circularity. The MarkForged® used Nylon White (PA6) to create the parts. ANOVA and the S/N ratio are also used to evaluate and optimize the influence of chosen factors. As a result, it was concluded that the hexagonal infill pattern, the thickness of 5 mm, wall layer of 2, and a layer height of 1.125 mm were known to be the optimal process parameters for circularity and cylindricity in experiments. Then a linear regression model was created to observe the relationship between the control variables with cylindricity and circularity. The results were confirmed by a confirmation test.

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Section: Introductionmentioning

confidence: 99%

Mathematical Modeling and Optimization of Fused Filament Fabrication (FFF) Process Parameters for Shape Deviation Control of Polyamide 6 Using Taguchi Method

et al. 2021

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“…Liquid-Solid phase change (or solidification/melting) and its interaction with the surrounding air are ubiquitous in various natural and/or industrial processes, e.g., latent thermal energy storage (LTES) systems [80,88], welding [65,13,101,74], casting [19,36], and additive manufacturing (AM) [64,32,53]. This motivates researchers to develop physical and high-fidelity models to further understand the complex physics and dynamics, and accurately predict the behavior of materials in order to produce high-quality products.…”

Section: Introductionmentioning

confidence: 99%

“…Most existing models for the thermo-gas-liquid-solid flows with liquid-solid phase change follow a similar procedure: The deforming gas-liquid interface is located by a certain interface capturing method and the continuous surface tension force is added, while the enthalpy-porosity technique is directly applied without any further changes to adapt to the appearance of a new phase. The volume-of-fluid method is the most popular choice and is used, e.g., in [80,74,49,97,64,88,32]. The level-set and conservative level set methods are recently used in [96] and [53], respectively.…”

Section: Introductionmentioning

confidence: 99%

“…The level-set and conservative level set methods are recently used in [96] and [53], respectively. Some additional physics are introduced to the models, e.g., the thermo-capillary effect [64,96,32,53] and recoil pressure [64,32,53]. Another recent model [99] follows the same strategy but instead uses the Phase-Field model in [70] for anisotropic solidification and the conservative Phase-Field method [18] as the interface capturing method.…”

Section: Introductionmentioning

confidence: 99%

“…(ii) The surface tension and drag forces can appear at the wrong location because the volume fractions, which are not clearly defined, are needed to compute the forces. Based on the formulations, e.g., in [74,64,96,53,32], the surface tension at the gas-liquid interface will falsely appear at the gas-solid interface, and the drag force will falsely appear in the gas phase when the local temperature is lower than the solidus temperature. Some artificial operations need to be added but they have seldom been mentioned in the literature.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

A consistent and conservative Phase-Field model for thermo-gas-liquid-solid flows including liquid-solid phase change

Huang,

Lin,

Ardekani

2021

Preprint

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In the present study, a consistent and conservative Phase-Field model is developed to study thermogas-liquid-solid flows with liquid-solid phase change. The proposed model is derived with the help of the consistency conditions and exactly reduces to the consistent and conservative Phase-Field method for incompressible two-phase flows, the fictitious domain Brinkman penalization (FD/BP) method for fluidstructure interactions, and the Phase-Field model of solidification of pure material. It honors the mass conservation, defines the volume fractions of individual phases unambiguously, and therefore captures the volume change due to phase change. The momentum is conserved when the solid phase is absent, but it changes when the solid phase appears due to the no-slip condition at the solid boundary. The proposed model also conserves the energy, preserves the temperature equilibrium, and is Galilean invariant. A novel continuous surface tension force to confine its contribution at the gas-liquid interface and a drag force modified from the Carman-Kozeny equation to reduce solid velocity to zero are proposed. The issue of initiating phase change in the original Phase-Field model of solidification is addressed by physically modifying the interpolation function. The corresponding consistent scheme is developed to solve the model, and the numerical results agree well with the analytical solutions and the existing experimental and numerical data. Two challenging problems having a wide range of material properties and complex dynamics are conducted to demonstrate the capability of the proposed model.

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Quantification of Interdependent Dynamics during Laser Additive Manufacturing Using X‐Ray Imaging Informed Multi‐Physics and Multiphase Simulation

et al. 2022

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Laser powder bed fusion (LPBF) can produce high-value metallic components for many industries; however, its adoption for safety-critical applications is hampered by the presence of imperfections. The interdependency between imperfections and processing parameters remains unclear. Here, the evolution of porosity and humps during LPBF using X-ray and electron imaging, and a high-fidelity multiphase process simulation, is quantified. The pore and keyhole formation mechanisms are driven by the mixing of high temperatures and high metal vapor concentrations in the keyhole is revealed. The irregular pores are formed via keyhole collapse, pore coalescence, and then pore entrapment by the solidification front. The mixing of the fast-moving vapor plume and molten pool induces a Kelvin-Helmholtz instability at the melt track surface, forming humps. X-ray imaging and a high-fidelity model are used to quantify the pore evolution kinetics, pore size distribution, waviness, surface roughness, and melt volume under single layer conditions. This work provides insights on key criteria that govern the formation of imperfections in LPBF and suggest ways to improve process reliability.

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Modeling and numerical studies of selective laser melting: Multiphase flow, solidification and heat transfer

Cited by 43 publications

References 38 publications

Mathematical Modeling and Optimization of Fused Filament Fabrication (FFF) Process Parameters for Shape Deviation Control of Polyamide 6 Using Taguchi Method

Mathematical Modeling and Optimization of Fused Filament Fabrication (FFF) Process Parameters for Shape Deviation Control of Polyamide 6 Using Taguchi Method

A consistent and conservative Phase-Field model for thermo-gas-liquid-solid flows including liquid-solid phase change

Quantification of Interdependent Dynamics during Laser Additive Manufacturing Using X‐Ray Imaging Informed Multi‐Physics and Multiphase Simulation

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