Numerical Simulations to Predict the Melt Pool Dynamics and Heat Transfer during Single-Track Laser Melting of Ni-Based Superalloy (CMSX-4)

Computational Fluid Dynamics (CFD) simulations are used in this work to study the dynamic behavior of the melt pool and heat transfer during the single-track laser melting process of a nickel-based superalloy (CMSX-4). To include the effects of powder inhomogeneities and obtain a realistic distribution of the powder layer on the bed chamber, the CFD model is coupled with a Discrete Element Method (DEM) solver. The coupled model is implemented in the open-source software package OpenFOAM. In the CFD model's governing equations, some key physical mechanisms, such as the Marangoni effect and recoil pressure, are considered. With the help of the coupled CFD-DEM model, we have investigated the effect of key process parameters, such as laser power, scanning speed of the laser, powder size, and powder shape, on the size and homogeneity of the melt pool. From the simulation results, it was discovered that high laser power and slow scanning speed create a deep and narrow keyhole that leads to porosity. In contrast, balling defects are found to be caused by a small melt pool obtained from fast scanning speeds and inadequate laser power.