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Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V

In order to track the free interface of the melt pool and understand the evolution of the melt pool, the flow of fluid, and the interface behavior of gas and liquid, a physical model is developed by using the VOF method in this paper. Its characteristics are a combined heat source model, including a...

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Autores principales: Xu, Yixuan, Zhang, Dongyun, Deng, Junyuan, Wu, Xuping, Li, Lingshan, Xie, Yinkai, Poprawe, Reinhart, Schleifenbaum, Johannes Henrich, Ziegler, Stephan
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9656971/
https://www.ncbi.nlm.nih.gov/pubmed/36363176
http://dx.doi.org/10.3390/ma15217585
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author Xu, Yixuan
Zhang, Dongyun
Deng, Junyuan
Wu, Xuping
Li, Lingshan
Xie, Yinkai
Poprawe, Reinhart
Schleifenbaum, Johannes Henrich
Ziegler, Stephan
author_facet Xu, Yixuan
Zhang, Dongyun
Deng, Junyuan
Wu, Xuping
Li, Lingshan
Xie, Yinkai
Poprawe, Reinhart
Schleifenbaum, Johannes Henrich
Ziegler, Stephan
author_sort Xu, Yixuan
collection PubMed
description In order to track the free interface of the melt pool and understand the evolution of the melt pool, the flow of fluid, and the interface behavior of gas and liquid, a physical model is developed by using the VOF method in this paper. Its characteristics are a combined heat source model, including a parabolic rotation and a cylindrical distribution, and a powder bed stochastic distributed model with powder particle size. The unit interface between the metallic and gas phase in the laser–powder interaction zone can only be loaded by the heat source. Only the first and second laser scanning tracks are simulated to reduce the calculation time. The simulation results show that process parameters such as laser power and scanning speed have significant effects on the fluid flow and surface morphology in the melt pool, which are in good agreement with the experimental results. Compared with the first track, the second track has larger melt pool geometry, higher melt temperature, and faster fluid flow. The melt flows intensely at the initial position due to the high flow rate in the limited melt space. Because there is enough space for the metal flow, the second track can obtain smooth surface morphology more easily compared to the first track. The melt pool temperature at the laser beam center fluctuates during the laser scanning process. This depends on the effects of the interaction between heat conduction or heat accumulation or the interaction between heat accumulation and violent fluid flow. The temperature distribution and fluid flow in the melt pool benefit the analysis and understanding of the evolution mechanism of the melt pool geometry and surface topography and further allow regulation of the L-PBF process of Ti6Al4V.
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spelling pubmed-96569712022-11-15 Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V Xu, Yixuan Zhang, Dongyun Deng, Junyuan Wu, Xuping Li, Lingshan Xie, Yinkai Poprawe, Reinhart Schleifenbaum, Johannes Henrich Ziegler, Stephan Materials (Basel) Article In order to track the free interface of the melt pool and understand the evolution of the melt pool, the flow of fluid, and the interface behavior of gas and liquid, a physical model is developed by using the VOF method in this paper. Its characteristics are a combined heat source model, including a parabolic rotation and a cylindrical distribution, and a powder bed stochastic distributed model with powder particle size. The unit interface between the metallic and gas phase in the laser–powder interaction zone can only be loaded by the heat source. Only the first and second laser scanning tracks are simulated to reduce the calculation time. The simulation results show that process parameters such as laser power and scanning speed have significant effects on the fluid flow and surface morphology in the melt pool, which are in good agreement with the experimental results. Compared with the first track, the second track has larger melt pool geometry, higher melt temperature, and faster fluid flow. The melt flows intensely at the initial position due to the high flow rate in the limited melt space. Because there is enough space for the metal flow, the second track can obtain smooth surface morphology more easily compared to the first track. The melt pool temperature at the laser beam center fluctuates during the laser scanning process. This depends on the effects of the interaction between heat conduction or heat accumulation or the interaction between heat accumulation and violent fluid flow. The temperature distribution and fluid flow in the melt pool benefit the analysis and understanding of the evolution mechanism of the melt pool geometry and surface topography and further allow regulation of the L-PBF process of Ti6Al4V. MDPI 2022-10-28 /pmc/articles/PMC9656971/ /pubmed/36363176 http://dx.doi.org/10.3390/ma15217585 Text en © 2022 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 (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Xu, Yixuan
Zhang, Dongyun
Deng, Junyuan
Wu, Xuping
Li, Lingshan
Xie, Yinkai
Poprawe, Reinhart
Schleifenbaum, Johannes Henrich
Ziegler, Stephan
Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V
title Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V
title_full Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V
title_fullStr Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V
title_full_unstemmed Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V
title_short Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V
title_sort numerical simulation in the melt pool evolution of laser powder bed fusion process for ti6al4v
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9656971/
https://www.ncbi.nlm.nih.gov/pubmed/36363176
http://dx.doi.org/10.3390/ma15217585
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