S𝔸𝕄PLE: A Software Suite to Predict Consolidation and Microstructure for Powder Bed Fusion Additive Manufacturing

Markl, Matthias; Rausch, Alexander M.; Küng, Vera E.; Körner, Carolin

doi:10.1002/adem.201901270

Cited by 13 publications

(10 citation statements)

References 38 publications

(113 reference statements)

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“…The present laser beam absorption model has been implemented within our numerical framework SAMPLE 2D . [ 10 ] This framework models the powder bed fusion process for electron as well as laser beam sources on the mesoscopic scale, i.e., each individual particle is resolved. This enables the software to account for melt pool dynamics, evaporation effects, and microstructure evolution.…”

Section: Exemplary Applicationmentioning

confidence: 99%

“…[ 9 ] The software SAMPLE 2D has been developed for the simulation of powder bed fusion additive manufacturing processes. [ 10 ] It focuses on the exposure of individual powder layers by the beam and the subsequent melting, consolidation, and solidification. The fundamental model was suggested by Körner et al [ 11 ] The simulation software originally focused on selective electron beam melting and it has been successfully validated by various experiments using different process parameters and different materials.…”

Section: Introductionmentioning

confidence: 99%

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Modeling Laser Beam Absorption of Metal Alloys at High Temperatures for Selective Laser Melting

et al. 2021

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Selective Laser Melting (SLM) is a promising technology to fabricate metallic components with complex geometries. However, determining process windows for specific materials and SLM machines by trial‐and‐error experiments is time consuming and expensive. Numerical simulation has been demonstrated as an efficient way to aid the process development. A crucial aspect is the absorption and reflection of the laser by the material. While there exist elaborated ray tracing approaches and absorption models, the most important drawback is to measure a reliable reflection coefficient of the material for different temperatures and phases. In this work, we discuss the application of a laser beam absorption model for SLM of metal alloys in the high temperature regime. The model bases on fundamental physical laws by taking reflection, refraction and absorption into account. The corresponding reflection coefficient is related to other physical quantities, like the electrical resistivity. The computed reflection coefficients are compared with reflection coefficient measurements of liquid NiFe alloys and with SLM of stainless steel 316L and Ti–6Al–4V. Finally, the laser beam absorption model is implemented in SAMPLE2D, a software for simulation of additive manufacturing on the powder scale, and is exemplary applied on single track melting experiments on compact Ti–6Al–4V plates.

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Section: Exemplary Applicationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modeling Laser Beam Absorption of Metal Alloys at High Temperatures for Selective Laser Melting

et al. 2021

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“…Numerical simulations were used to analyze the solidification conditions during SEBM as a function of the processing parameters. The simulations were conducted using the 2D version of our in-house software tool, SAMPLE 2D (Simulation of Additive Manufacturing on the Powder scale using a Laser or Electron beam), which is described elsewhere in detail [14]. It is based on a Lattice Boltzmann framework that solves full hydrodynamics in the melt pool, and thermodynamics in the entire domain.…”

Section: Methodsmentioning

confidence: 99%

“…Numerical simulations of the SEBM process using our in-house software SAMPLE 2D [14] were performed to reveal the solidification conditions for all hatching strategies. The parameters listed in Table 1 were used.…”

Section: Numerical Simulationmentioning

confidence: 99%

Fabrication of Single Crystals through a µ-Helix Grain Selection Process during Electron Beam Metal Additive Manufacturing

Gotterbarm

Rausch

Körner

2020

Metals

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Selective Electron Beam Melting (SEBM) is a powder bed-based additive manufacturing process for metals. As the electron beam can be moved inertia-free by electromagnetic lenses, the solidification conditions can be deliberately adjusted within the process. This enables control over the local solidification conditions. SEBM typically leads to columnar grain structures. Based on numerical simulation, we demonstrated how technical single crystals develop in IN718 by forcing the temperature gradient along a µ-Helix. The slope of the µ-Helix, i.e., the deviation of the thermal gradient from the build direction, determined the effectiveness of grain selection right up to single crystals. used as the model alloy to fabricate technical single crystals via SEBM. The solidification conditions were subsequently analyzed using numerical simulations of the process.

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“…To investigate the nucleation mechanism, a simulation with our inhouse software SAMPLE 2D [35] was performed. The software is based on a 2D lattice Boltzmann method that inherits melt-pool dynamics, melting/solidification, element-distribution variations, and evaporation.…”

Section: Setupmentioning

confidence: 99%

New Grain Formation by Constitutional Undercooling Due to Remelting of Segregated Microstructures during Powder Bed Fusion

et al. 2020

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A microstructure has significant influence on the mechanical properties of parts. For isotropic properties, the formation of equiaxed microstructures by the nucleation of new grains during solidification is necessary. For conventional solidification processes, nucleation is well-understood. Regarding powder bed fusion, the repeated remelting of previous layers can cause nucleation under some conditions that are not explainable with classical theories. Here, we investigate this nucleation mechanism with an unprecedented level of detail. In the first step, we built samples with single crystalline microstructures from Ni-base superalloy IN718 by selective electron beam melting. In the second step, single lines with different parameters were molten on top of these samples. We observed a huge number of new grains by nucleation at the melt-pool border of these single lines. However, new grains can only prevail if the alignment of their crystallographic orientation with respect to the local temperature gradient is superior to that of the base material. The current hypothesis is that nucleation at the melt-pool border happens due to remelting microsegregations from former solidification processes leading to constitutional undercooling directly at the onset of solidification. This study offers the opportunity to understand and exploit this mechanism for different manufacturing processes.

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S𝔸𝕄PLE: A Software Suite to Predict Consolidation and Microstructure for Powder Bed Fusion Additive Manufacturing

Cited by 13 publications

References 38 publications

Modeling Laser Beam Absorption of Metal Alloys at High Temperatures for Selective Laser Melting

Modeling Laser Beam Absorption of Metal Alloys at High Temperatures for Selective Laser Melting

Fabrication of Single Crystals through a µ-Helix Grain Selection Process during Electron Beam Metal Additive Manufacturing

New Grain Formation by Constitutional Undercooling Due to Remelting of Segregated Microstructures during Powder Bed Fusion

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