A comprehensive study on thermal modeling of SLM process under conduction mode using FEM
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ORIGINAL ARTICLE
A comprehensive study on thermal modeling of SLM process under conduction mode using FEM E. L. Papazoglou 1 & N. E. Karkalos 1 & A. P. Markopoulos 1 Received: 6 July 2020 / Accepted: 19 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Selective laser melting (SLM) has emerged as one of the leading additive manufacturing (AM) processes for the fabrication of complex metallic components, due to its capability to achieve high quality at acceptable times. However, due to the complexity of physical phenomena occurring during SLM, such as heat transfer and phase transformations, laser absorption, molten metal flow, and moving interfaces, it is still necessary to conduct research in order to achieve a deeper understanding of the process and improve it. In the present work, a comprehensive simulation model for the study of conduction mode single-track SLM process of 316L stainless steel is presented. This model incorporates temperature and phase-dependent material properties for both powder bed and substrate, detailed calculation of the absorption coefficient, and temperature-dependent boundary conditions. The simulation results are in excellent agreement with experimental findings, regarding the morphology and dimensions of melt pool under various process conditions. Moreover, with the proposed model, analysis of power losses as well as cooling and heating rates is conducted, identifying the characteristics of SLM process and providing valuable insights for its optimization. Keywords Selective laser melting . Finite element method . Single track . Balling formation . Melt pool characteristics
1 Introduction Additive manufacturing (AM) can be defined as the process of producing parts from a three-dimensional data model, by joining or adding material using the layer-by-layer principle [1]. The physical AM process is relatively simple as it consists of only two steps: the generation of a single layer, with specific shape and thickness based on slice data coming from a 3D CAD model, and the joining of each new layer on top of the preceding one [2]. There are various AM processes and they can be classified according to the type of the energy source, the type and form of the material, and the bonding means and techniques that they use. The laser-powder bed fusion (LPBF) processes, such as selective laser melting (SLM), are found and considered more promising than the solid-based ones [1]. AM is a revolutionizing product development and manufacturing technology that may reform the whole
* A. P. Markopoulos [email protected] 1
School of Mechanical Engineering, Section of Manufacturing Technology, National Technical University of Athens, Heroon Polytechniou 9, 15780 Athens, Greece
manufacturing industry. The rapid character of AM technology, the capability of building parts regardless of their shape complexity in a single step within an AM machine, and the inherent flexibility of the process make AM a promising manufacturing technique, competitive to the traditional subtract
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