Select laser melting of W–Ni–Fe powders: simulation and experimental study

Zhang, D. Q.; Cai, Qizhou; Liu, Jihong; Zhang, L.; Li, R. D.

doi:10.1007/s00170-010-2641-3

Cited by 95 publications

(43 citation statements)

References 18 publications

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“…Components that remained attached to the base plate contained stress levels near to that of the material yield strength, whereas components removed from the base plate had lower stress levels -and yet deformation was present [5]. One way to minimise the degree of temperature gradients (which seem to cause the high residual stresses) is to equip the sintering machine with a heated powder bed that reduces the severity of the temperature gradient around the laser spot [21].…”

Section: Discussionmentioning

confidence: 99%

Residual Stress Measurements and Structural Integrity Implications for Selective Laser Melted Ti-6al-4v

Knowles

Becker

2012

sajie

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Selective laser melting (SLM) of Ti-6Al-4V has significant potential in the aerospace and biotechnology industries. SLM employs a focused laser beam to melt successive layers of metallic powder into complex components. This process can result in the generation of high thermally-induced residual stresses. These residual stresses, together with micro-flaws/ pores from the inherent fabrication process, may lead to premature fatigue crack initiation and propagation at relatively low cyclic stresses. The hole-drilling strain gauge method was used to evaluate residual stresses within SLM Ti-6Al-4V specimens, with the intention of understanding the associated mechanisms for the successful application of SLM Ti-6Al-4V in industry. OPSOMMING'Selective laser melting' (SLM) van Ti-6Al-4V het aansienlike potentiaal in die lugvaart en biotegnologiese bedrywe. SLM maak gebruik van 'n gekonsentreerde laser straal om agtereenvolgende lae metaal poeier te smelt en sodoende intrieke metal komponente te vorm. Gedurende SLM kan hoë resterende spanning veroorsaak word as gevolg van hoë temperature. Hierdie spanning, asook mikrodefekte wat gedurende die vormingsproses ontstaan, mag lei tot voortydige materiaalverswakking deur spleet vorming en verspreiding gedurende betreklik lae sikliese spannings. Resterende spanning in Ti-6Al-4V eksemplare is bereken deur 'n boor-versonke rekstrokie metode om sodoende die meganismes verantwoordelik vir die suksessvolle toepassing van SLM in die Ti-6Al-4V bedryf te bepaal.

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Section: Discussionmentioning

confidence: 99%

Residual Stress Measurements and Structural Integrity Implications for Selective Laser Melted Ti-6al-4v

Knowles

Becker

2012

sajie

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“…However, the mesh used in this strategy was nonconforming along the interface between the coarse and fine mesh regions, which could produce unphysical stiffness matrices compared to their conformal mesh counterparts. 45 An ANSYS model for simulation of the melting of W-Ni-Fe powder was studied by Zhang et al 46 The dimensions of the substrate and powder bed were 2 mm × 3 mm × 1.5 mm and 1 mm × 2 mm × 0.5 mm, respectively. The substrate was meshed using tetrahedral elements, whereas the powder was meshed using hexahedral elements.…”

Section: Literature Review Of Thermal Finite Element Methods For Selecmentioning

confidence: 99%

Projection Microstereolithography as a Micro-Additive Manufacturing Technology: Processes, Materials, and Applications

Srivatsan¹,

Sudarshan²

2015

Additive Manufacturing

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“…The Gaussian mathematical form most widely used in the literature 1,5,8,10,27 is described in equations (5) and (6) …”

Section: Laser Beam Approximationmentioning

confidence: 99%

Comparison of 3DSIM thermal modelling of selective laser melting using new dynamic meshing method to ANSYS

Zeng

Pal

Gong

et al. 2015

Materials Science and Technology

102

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Selective laser melting (SLM) is an additive manufacturing (AM) process in which parts are fabricated by selectively melting regions of the surface of a metallic powder bed in a layer-bylayer fashion. Various thermal phenomena such as heat conduction, convection, radiation, melting and solidification, dynamic phase changes, and evaporation occur during the SLM process. In addition, laser intensity and powder bed scan speeds during processing complicate understanding of the process due to complex dynamic interactions between the powder bed and laser. In order to study these dynamic interactions, a finite element model has been developed which uses a dynamic mesh with spatial non-linear thermal properties to track the point of laser exposure on the powder bed to study thermal evolution during SLM. The model is able to achieve a refined, localised mesh in the melt zone and heat affected zone (HAZ), surrounded by a relatively coarse mesh outside of the HAZ regions. The dynamic meshing for this implementation is achieved using both the sub-modelling functionality in ANSYS and a new set of algorithms being commercialised by 3DSIM, LLC. It was found that dynamic meshing reduces the model size and computational burden. In this paper, the use of the sub-modelling approach for dynamic meshing was verified by comparing it against a uniform fine mesh model. The results of the two models match within an acceptable tolerance. Also, a mesh sensitivity analysis was carried out in order to show solution convergence as a function of increasing mesh density. The results of this analysis were also validated using experiments to show a match between experimental and simulated melt pools. Finally, the ANSYS solution was compared with a new set of dynamic meshing finite element analysis algorithms running in Matlab. It was found that these new algorithms were significantly faster than their ANSYS counterparts for solving problems using a dynamic mesh.

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Select laser melting of W–Ni–Fe powders: simulation and experimental study

Cited by 95 publications

References 18 publications

Residual Stress Measurements and Structural Integrity Implications for Selective Laser Melted Ti-6al-4v

Residual Stress Measurements and Structural Integrity Implications for Selective Laser Melted Ti-6al-4v

Projection Microstereolithography as a Micro-Additive Manufacturing Technology: Processes, Materials, and Applications

Comparison of 3DSIM thermal modelling of selective laser melting using new dynamic meshing method to ANSYS

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