激光粉末床熔融模拟中粒度对粉末堆积特性和熔池尺寸的影响

IF 3.3 Q2 ENGINEERING, MANUFACTURING Journal of Manufacturing and Materials Processing Pub Date : 2024-04-01 DOI:10.3390/jmmp8020071
Jun Katagiri, S. Nomoto, M. Kusano, Makoto Watanabe
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引用次数: 0

摘要

在激光粉末床熔化(L-PBF)过程中会产生各种缺陷,这些缺陷会影响制造部件的质量。以往的研究表明,形成的缺陷与熔池尺寸有关。在 L-PBF 过程中,粉末颗粒会薄薄地铺在基底上;因此,粉末的堆积特性会影响熔池尺寸。本研究通过数值模拟评估了颗粒大小对粉末填料特性和熔池尺寸的影响。使用平均直径 (Dav) 为 24、28、32、36 和 40 μm 的不同颗粒,进行了一系列离散元素法 (DEM) 模拟。随着直径变小,DEM 模拟得到的堆积分数也变高。小 Dav 时,几个颗粒堆积在一起,而大 Dav 时,颗粒几乎以一个颗粒直径的厚度扩散。此外,Dav 大时,堆积结构不均匀且稀疏。由于多物理场计算流体动力学(CFD)模拟将颗粒位置作为初始固体金属体积,因此得到的熔池宽度几乎与Dav无关,大致相当于模拟中使用的激光光斑尺寸。相反,熔池深度随着 Dav 的减小而减小。即使粉末床厚度相同,小颗粒也会通过堆积形成复杂的堆积结构,从而产生较大的比表面积。与几乎只有一个颗粒厚度的大颗粒涂层相比,这会导致复杂的激光反射。这种复杂的反射会吸收激光照射在基底上形成的粉末床内部所产生的热量。因此,对于小颗粒来说,在基底下方形成的熔池深度会减小。
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Particle Size Effect on Powder Packing Properties and Molten Pool Dimensions in Laser Powder Bed Fusion Simulation
Various defects are produced during the laser powder bed fusion (L-PBF) process, which can affect the quality of the fabricated part. Previous studies have revealed that the defects formed are correlated with molten pool dimensions. Powder particles are thinly spread on a substrate during the L-PBF process; hence, powder packing properties should influence the molten pool dimensions. This study evaluated the influence of particle size on powder packing properties and molten pool dimensions obtained through numerical simulations. Using particles with different average diameters (Dav) of 24, 28, 32, 36, and 40 μm, a series of discrete-element method (DEM) simulations were performed. The packing fraction obtained from DEM simulations became high as Dav became small. Several particles piled up for small Dav, whereas particles spread with almost one-particle diameter thickness for large Dav. Moreover, the packing structure was inhomogeneous and sparse for large Dav. As a result of multiphysics computational fluid dynamics (CFD) simulations incorporating particles’ positions as initial solid metal volume, the molten pool width obtained was hardly dependent on the Dav and was roughly equivalent to the laser spot size used in the simulations. In contrast, the molten pool depth decreased as Dav decreased. Even if the powder bed thickness is the same, small particles can form a complex packing structure by piling up, resulting in a large specific surface area. This can lead to a complex laser reflection compared to the large particles coated with almost one-particle thickness. The complex reflection absorbs the heat generated by laser irradiation inside the powder bed formed on the substrate. As a result, the depth of the molten pool formed below the substrate is reduced for small particles.
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来源期刊
Journal of Manufacturing and Materials Processing
Journal of Manufacturing and Materials Processing Engineering-Industrial and Manufacturing Engineering
CiteScore
5.10
自引率
6.20%
发文量
129
审稿时长
11 weeks
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