Particle-based modelling of laser powder bed fusion of metals with emphasis on the melting mode transition

IF 2.4 3区工程技术 Granular Matter Pub Date : 2024-06-13 DOI:10.1007/s10035-024-01442-2

Claas Bierwisch, Bastien Dietemann, Tim Najuch

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Abstract

The laser-beam powder bed fusion process for metals, commonly abbreviated as PBF-LB/M, is a widely used process for the additive manufacturing of parts. Numerical simulations are useful to identify optimal process parameters for different materials and to obtain detailed insights into process dynamics. The present work uses a single-phase incompressible Smoothed Particle Hydrodynamics (SPH) scheme to model PBF-LB/M which was found to reduce the required computational time and significantly stabilize the partially violent flow in the melt pool in comparison to a weakly compressible SPH approach. The laser-material interaction is realistically modelled by means of a ray tracing method. An approach to model the effective thermal coductivity of the powder bed is proposed. Excellent agreement between the simulation results and experimental X-ray analyses of the transition from conduction melting mode to keyhole mode including geometric properties of the vapor depression zone was found. These results prove the usability of SPH as a high precision simulation tool for PBF-LB/M.

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基于粒子的金属激光粉末床熔融建模，重点关注熔融模式转变

金属激光束粉末床熔融工艺（通常缩写为 PBF-LB/M）是一种广泛应用于零件增材制造的工艺。数值模拟有助于确定不同材料的最佳工艺参数，并深入了解工艺动态。本研究采用单相不可压缩平滑粒子流体动力学（SPH）方案来模拟 PBF-LB/M，与弱可压缩 SPH 方法相比，该方案可减少所需的计算时间，并显著稳定熔池中的部分暴力流。激光与材料之间的相互作用是通过射线追踪方法真实模拟的。还提出了粉末床有效热导率的建模方法。模拟结果与从传导熔化模式过渡到锁孔模式的实验 X 射线分析结果（包括蒸汽凹陷区的几何特性）非常吻合。这些结果证明了 SPH 作为 PBF-LB/M 高精度模拟工具的可用性。

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来源期刊

Granular Matter MATERIALS SCIENCE, MULTIDISCIPLINARY-MECHANICS

CiteScore

4.30

自引率

8.30%

发文量

期刊介绍： Although many phenomena observed in granular materials are still not yet fully understood, important contributions have been made to further our understanding using modern tools from statistical mechanics, micro-mechanics, and computational science. These modern tools apply to disordered systems, phase transitions, instabilities or intermittent behavior and the performance of discrete particle simulations. >> Until now, however, many of these results were only to be found scattered throughout the literature. Physicists are often unaware of the theories and results published by engineers or other fields - and vice versa. The journal Granular Matter thus serves as an interdisciplinary platform of communication among researchers of various disciplines who are involved in the basic research on granular media. It helps to establish a common language and gather articles under one single roof that up to now have been spread over many journals in a variety of fields. Notwithstanding, highly applied or technical work is beyond the scope of this journal.