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The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder

In the selective laser melting process, metal powder melted by the laser heat source generates large instantaneous energy, resulting in transient high temperature and complex stress distribution. Different temperature gradients and anisotropy finally determine the microstructure after melting and af...

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Autores principales: Duan, Xianyin, Chen, Xinyue, Zhu, Kunpeng, Long, Tao, Huang, Shiyang, Jerry, Fuh Y H
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8036308/
https://www.ncbi.nlm.nih.gov/pubmed/33805355
http://dx.doi.org/10.3390/ma14071673
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author Duan, Xianyin
Chen, Xinyue
Zhu, Kunpeng
Long, Tao
Huang, Shiyang
Jerry, Fuh Y H
author_facet Duan, Xianyin
Chen, Xinyue
Zhu, Kunpeng
Long, Tao
Huang, Shiyang
Jerry, Fuh Y H
author_sort Duan, Xianyin
collection PubMed
description In the selective laser melting process, metal powder melted by the laser heat source generates large instantaneous energy, resulting in transient high temperature and complex stress distribution. Different temperature gradients and anisotropy finally determine the microstructure after melting and affect the build quality and mechanical properties as a result. It is important to monitor and investigate the temperature and stress distribution evolution. Due to the difficulties in online monitoring, finite element methods (FEM) are used to simulate and predict the building process in real time. In this paper, a thermo-mechanical coupled FEM model is developed to predict the thermal behaviors of the melt pool by using Gaussian moving heat source. The model could simulate the shapes of the melt pool, distributions of temperature and stress under different process parameters through FEM. The influences of scanning speed, laser power, and spot diameter on the distribution of the melt pool temperature and stress are investigated in the SLM process of Al6063, which is widely applied in aerospace, transportation, construction and other fields due to its good corrosion resistance, sufficient strength and excellent process performance. Based on transient analysis, the relationships are identified among these process parameters and the melt pool morphology, distribution of temperature and thermal stress. It is shown that the maximum temperature at the center point of the scanning tracks will gradually increase with the increment of laser power under the effect of thermal accumulation and heat conduction, as the preceded scanning will preheat the subsequent scanning tracks. It is recommended that the parameters with optimized laser power (P = 175–200 W), scanning speed (v = 200–300 mm/s) and spot diameter (D = 0.1–0.15 mm) of aluminum alloy powder can produce a high building quality of the SLM parts under the pre-set conditions.
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spelling pubmed-80363082021-04-12 The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder Duan, Xianyin Chen, Xinyue Zhu, Kunpeng Long, Tao Huang, Shiyang Jerry, Fuh Y H Materials (Basel) Article In the selective laser melting process, metal powder melted by the laser heat source generates large instantaneous energy, resulting in transient high temperature and complex stress distribution. Different temperature gradients and anisotropy finally determine the microstructure after melting and affect the build quality and mechanical properties as a result. It is important to monitor and investigate the temperature and stress distribution evolution. Due to the difficulties in online monitoring, finite element methods (FEM) are used to simulate and predict the building process in real time. In this paper, a thermo-mechanical coupled FEM model is developed to predict the thermal behaviors of the melt pool by using Gaussian moving heat source. The model could simulate the shapes of the melt pool, distributions of temperature and stress under different process parameters through FEM. The influences of scanning speed, laser power, and spot diameter on the distribution of the melt pool temperature and stress are investigated in the SLM process of Al6063, which is widely applied in aerospace, transportation, construction and other fields due to its good corrosion resistance, sufficient strength and excellent process performance. Based on transient analysis, the relationships are identified among these process parameters and the melt pool morphology, distribution of temperature and thermal stress. It is shown that the maximum temperature at the center point of the scanning tracks will gradually increase with the increment of laser power under the effect of thermal accumulation and heat conduction, as the preceded scanning will preheat the subsequent scanning tracks. It is recommended that the parameters with optimized laser power (P = 175–200 W), scanning speed (v = 200–300 mm/s) and spot diameter (D = 0.1–0.15 mm) of aluminum alloy powder can produce a high building quality of the SLM parts under the pre-set conditions. MDPI 2021-03-29 /pmc/articles/PMC8036308/ /pubmed/33805355 http://dx.doi.org/10.3390/ma14071673 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/ (https://creativecommons.org/licenses/by/4.0/) ).
spellingShingle Article
Duan, Xianyin
Chen, Xinyue
Zhu, Kunpeng
Long, Tao
Huang, Shiyang
Jerry, Fuh Y H
The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder
title The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder
title_full The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder
title_fullStr The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder
title_full_unstemmed The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder
title_short The Thermo-Mechanical Coupling Effect in Selective Laser Melting of Aluminum Alloy Powder
title_sort thermo-mechanical coupling effect in selective laser melting of aluminum alloy powder
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8036308/
https://www.ncbi.nlm.nih.gov/pubmed/33805355
http://dx.doi.org/10.3390/ma14071673
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