Revealing formation mechanism of end of process depression in laser powder bed fusion by multi-physics meso-scale simulation

被引:2
|
作者
Chen, Haodong [1 ,2 ]
Lin, Xin [1 ,2 ,3 ]
Sun, Yajing [4 ]
Wang, Shuhao [1 ,2 ]
Zhu, Kunpeng [1 ,2 ,3 ]
Dan, Binbin [1 ,2 ]
机构
[1] Wuhan Univ Sci & Technol, Precis Mfg Inst, Wuhan 430081, Peoples R China
[2] Wuhan Univ Sci & Technol, Key Lab Met Equipment & Control Technol, Minist Educ, Wuhan 430081, Peoples R China
[3] Chinese Acad Sci, Hefei Inst Phys Sci, Inst Intelligent Machines, Huihong Bldg,Changwu Middle Rd 801, Changzhou 213164, Jiangsu, Peoples R China
[4] Wuhan Univ Technol, Hubei Key Lab Theory & Applicat Adv Mat Mech, Wuhan, Peoples R China
基金
中国国家自然科学基金;
关键词
Additive manufacturing; laser powder bed fusion; meso-scale simulation; end-of-process depression; multi-physics simulation; HEAT-TRANSFER; BEHAVIOR; MICROSTRUCTURE;
D O I
10.1080/17452759.2024.2326599
中图分类号
T [工业技术];
学科分类号
08 ;
摘要
Unintended end-of-process depression (EOPD) commonly occurs in laser powder bed fusion (LPBF), leading to poor surface quality and lower fatigue strength, especially for many implants. In this study, a high-fidelity multi-physics meso-scale simulation model is developed to uncover the forming mechanism of this defect. A defect-process map of the EOPD phenomenon is obtained using this simulation model. It is found that the EOPD formation mechanisms are different under distinct regions of process parameters. At low scanning speeds in keyhole mode, the long-lasting recoil pressure and the large temperature gradient easily induce EOPD. While at high scanning speeds in keyhole mode, the shallow molten pool morphology and the large solidification rate allow the keyhole to evolve into an EOPD quickly. Nevertheless, in the conduction mode, the Marangoni effects along with a faster solidification rate induce EOPD. Finally, a 'step' variable power strategy is proposed to optimise the EOPD defects for the case with high volumetric energy density at low scanning speeds. This work provides a profound understanding and valuable insights into the quality control of LPBF fabrication.
引用
收藏
页数:15
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