Towards the simulation of Selective Laser Melting processes via phase transformation models

Bartel, Thorsten; Guschke, Isabelle; Menzel, Andreas

doi:10.1016/j.camwa.2018.08.032

Cited by 27 publications

(27 citation statements)

References 23 publications

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“…In addition, an internal strategy of Abaqus (*Model Change) is used to model the layer construction during the SLM process. For further information, see [2] and the references cited therein.…”

Section: Implementation and Algorithmic Treatmentmentioning

confidence: 99%

“…Based on the framework for solid-solid phase transformations in shape memory alloys, see e.g. [3], this contribution focuses on the advancement of the model presented in [2]. The model is based on the explicit consideration of phase energy densities, where each state of the material-powder, molten and re-solidified-is a single phase (see Fig.…”

Section: Introductionmentioning

confidence: 99%

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A computational phase transformation model for selective laser melting processes

2020

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Selective laser melting (SLM) has gained large interest due to advanced manufacturing possibilities. However, the growing potential also necessitates reliable predictions of structures in particular regarding their long-term behaviour. The constitutive and structural response is thereby challenging to reproduce, due to the complex material behaviour. This motivates the aims of this contribution: To establish a material model that accounts for the behaviour of the different phases occurring during SLM but that still allows the use of (basic) process simulations. In particular, the present modelling framework explicitly takes into account the mass fractions of the different phases, their mass densities, and specific inelastic strain contributions. The thermomechanically fully coupled framework is implemented into the software Abaqus. The numerical examples emphasise the capabilities of the framework to predict, e.g., the residual stresses occurring in the final part. Furthermore, a postprocessing of averaged inelastic strains is presented yielding a micromechanics-based motivation for inherent strains.

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Section: Implementation and Algorithmic Treatmentmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A computational phase transformation model for selective laser melting processes

2020

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“…Altogether, this establishes a physically well-motivated material model, where the different states of the material, namely powder, molten, and re-solidified, are captured as single phases weighted by respective volume fractions. To gain further insight into this material model, the interested reader is referred to [2].…”

Section: Constitutive Frameworkmentioning

confidence: 99%

A thermomechanical modelling framework for selective laser melting based on phase transformations

Guschke

Bartel

Menzel

2019

Proc Appl Math and Mech

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SLM (selective laser melting) is one of many processes belonging to the additive manufacturing sector, where a laser beam completely melts the particles of the manufactured part layer by layer. In contrast to common models, this framework is based on the minimisation of the free energy density where the phase transformation from powder to molten pool to re‐solidified material is modelled explicitly. The goal is to develop a more sophisticated model which is based on the material behaviour itself rather than on the use of temperature dependent material parameters. The following model is adapted from phase transformations in shape memory alloys, cf. [1]. With this at hand, more insight into the process is gained and the deformation as well as the residual stresses are predictable.

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“…The same modeling approach is applied in the full-scale layer-wise AM model developed by AlMangour et al [17] for the study of the printing process of TiC-reinforced 316L stainless steel. The solution of thermo-mechanical problem induced, moreover, the development of numerical tools of practical application, in order calculate process-induced stresses and strains based on the detailed temperature field [16], also taking into account the influences of the microstructure transformations [18].More sophisticated multi-physical approaches intimately describe and give insights on complex phenomena underlying the mechanisms of powder bed melting, solidification and consolidation in SLM, at the scale of the single powder particles [19,20]. The mechanism of formation of keyhole porosities has been also visualized through thermo-fluid dynamic modeling [21].The scope of the work described in this paper is to create a modelling tool for generating processing maps of metal alloys applicable to the laser powder bed melting technology.…”

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confidence: 99%

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confidence: 99%

Laser Operating Windows Prediction in Selective Laser-Melting Processing of Metallic Powders: Development and Validation of a Computational Fluid Dynamics-Based Model

Ridolfi¹,

Folgarait²,

Schino

2020

Materials

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The rapidly ascending trend of additive manufacturing techniques requires a tailoring of existing solidification models and the development of new numerical tools. User-friendly numerical models can be a valid aid in order to optimize operating parameter ranges with the scope to extend the modelling tools to already existing or innovative alloys. In this paper a modelling approach is described simulating the generation of single tracks on a powder bed system in a selective laser melting process. The approach we report attains track geometry as a function of: alloy thermo-physical properties, laser speed and power, powder bed thickness. Aim of the research is to generate a numerical tool able to predict laser power and speed ranges in manufacturing porosity-free printed parts without lack of fusion and keyhole pores. The approach is based on a simplified description of the physical aspects. Main simplifications concern: the laser energy input, the formation of the pool cavity, and the powder bed thermo-physical properties. The model has been adjusted based on literature data providing the track’s geometry (width and depth) and relative density. Such data refer to different alloys. In particular, Ti6Al4V, Inconel625, Al7050, 316L and pure copper are considered. We show that the printing process presents features common to all alloys. This allows the model to predict the printing behavior of an alloy from its physical properties, avoiding the need to perform specific experimental activities.

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Towards the simulation of Selective Laser Melting processes via phase transformation models

Cited by 27 publications

References 23 publications

A computational phase transformation model for selective laser melting processes

A computational phase transformation model for selective laser melting processes

A thermomechanical modelling framework for selective laser melting based on phase transformations

Laser Operating Windows Prediction in Selective Laser-Melting Processing of Metallic Powders: Development and Validation of a Computational Fluid Dynamics-Based Model

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