Heat Transfer, Molten Pool Flow Micro-Simulation, and Experimental Research on Molybdenum Alloys Fabricated via Selective Laser Melting

Molybdenum-based alloys fabricated via selective laser melting are considered to represent the next generation of high-temperature structural materials, but the additive manufacturing technology aiming at refractory alloys has not been explored extensively. Multi-field coupling simulation can be used as a practical tool to simulate a single track of molybdenum alloy printed via selective laser melting, observe the topography of the molten pool over time, and determine the effect of Marangoni flow on defect suppression. In this study, the t(melt), t(vapor), and the competition mechanism of spreading/solidification time were considered, the dominant spreading time was calculated, and a reasonable process parameter window for fabricating molybdenum alloy was obtained. It was found that keeping the energy density in the range of 3.1 x 10(11) J/m(3)-4.0 x 10(11) J/m(3) could better maintain appropriate melt channel depth and width and was beneficial to the droplet spreading behavior. This range was deemed suitable for printing molybdenum alloy.