Numerical investigation of thermal behavior and melt pool morphology in multi-track multi-layer selective laser melting
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ORIGINAL ARTICLE
Numerical investigation of thermal behavior and melt pool morphology in multi-track multi-layer selective laser melting of the 316L steel Saad Waqar 1,2 & Qidong Sun 1,2 &
Jiangwei Liu
3
&
Kai Guo 1,2 & Jie Sun 1,2
Received: 29 August 2020 / Accepted: 4 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Rapid melting and solidification of powder particles through a high-power laser is the characteristic feature of selective laser melting (SLM), which controls the material and physical properties of fabricated components. Considering the multi-track multilayer nature of an actual SLM process, an investigation of thermal behavior and melt pool morphology in multi-track multi-layer SLM of the 316L steel is presented in this paper. The SLM process of a four-layer component with multiple tracks was modeled. Element birth and death technique was used to simulate the layer built-up process. The established FEM model was used to investigate the variations in thermal variables and melt pool morphology with increasing number of layers. Moreover, the influence of various processing parameters in a multi-track multi-layer SLM was also studied. The results show that maximum melt pool temperature, melt pool width, and melt pool depth increase with increasing number of layers, whereas heating rates and cooling rates decrease with increasing number of layers. Compared with the previous layer, melt pool lifetime was observed to have a decreasing trend for layer 2 and increasing trend for layers 3 and 4. An increase in melt pool depth and decrease in melt pool width was observed by increasing hatch spacing. Furthermore, it was found that increasing laser power and scanning speeds both increase the heating and cooling rates. Keywords SLM . Melt pool . FEM . Thermal behavior . Melt pool morphology
1 Introduction Selective laser melting (SLM) is a promising additive manufacturing (AM) technique to fabricate complex metallic components with final shape and geometry. In SLM, powder particles of metals and their alloys are selectively melted through a high-energy laser beam. The melted powder particles then fuse together and re-solidify to form the desired shape. This process is * Kai Guo [email protected] * Jie Sun [email protected] 1
Key Laboratory of High Efficiency and Clean Mechanical Manufacture, School of Mechanical Engineering, Shandong University, Jinan 250061, China
2
Research Centre for Aeronautical Component Manufacturing Technology and Equipment, Jinan, China
3
School of Energy and Power Engineering Shandong University Jinan 250061 China
repeated layer by layer until the final geometry is attained [1, 2]. The repeated melting and solidification phenomena create a complex thermal gradient that influences the microstructure and mechanical behavior of the manufactured components [3, 4]. Therefore, an accurate assessment of thermal and solidification variables during the SLM process can help in predicting and controlling the behavior of fabricated components [5,
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