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Semi-analytical formulation for single-track laser powder-bed fusion process to estimate melt-pool characteristics considering fluid-flow and marangoni effect
https://orcid.org/http://orcid.org/0000-0003-2156-4860
The Laser-Based Powder Bed Fusion (LPBF) process is an additive manufacturing (AM) technique used to fabricate intricate 3D metallic components from fine powder particles. This study presents a 2D semi-analytical model, an algorithm developed by incorporating multiple physical phenomena of the process, i.e., heat transfer, fluid flow, and Marangoni effect for computing temperature and velocity distribution, to estimate the melt-pool characteristics for the single-track melting. The laser input energy has been modelled as a moving Gaussian volumetric heat source, and the fluid flow phenomenon has been formulated by ‘Semi-Implicit Method for Pressure Linked Equations’ (SIMPLE) method. A set of two-dimensional transient conservation of mass, momentum, and energy equations are discretized as co-located mesh by Finite Volume Method (FVM) and iteratively solved by Alternating Direction Implicit (ADI) scheme to obtain temperature and velocity field. The Pressure Weighted Interpolation Method (PWIM) is incorporated to avoid pressure oscillation and allow the use of co-located mesh for fluid flow, making the model computationally efficient. The model is validated for Ti6Al4V and Inconel 718 alloy with the experimental findings from the literature. The obtained results are in good agreement with an average deviation of 5.78% and 20.07% for Ti6Al4V , whereas for Inconel 718, 7.87 and 19.53% for melt-pool depth and width, respectively, were observed. Subsequently, the melt-pool growth and characteristics influenced by various process parameters are also studied.
Semi-analytical formulation for single-track laser powder-bed fusion process to estimate melt-pool characteristics considering fluid-flow and marangoni effect
https://orcid.org/http://orcid.org/0000-0003-2156-4860
The Laser-Based Powder Bed Fusion (LPBF) process is an additive manufacturing (AM) technique used to fabricate intricate 3D metallic components from fine powder particles. This study presents a 2D semi-analytical model, an algorithm developed by incorporating multiple physical phenomena of the process, i.e., heat transfer, fluid flow, and Marangoni effect for computing temperature and velocity distribution, to estimate the melt-pool characteristics for the single-track melting. The laser input energy has been modelled as a moving Gaussian volumetric heat source, and the fluid flow phenomenon has been formulated by ‘Semi-Implicit Method for Pressure Linked Equations’ (SIMPLE) method. A set of two-dimensional transient conservation of mass, momentum, and energy equations are discretized as co-located mesh by Finite Volume Method (FVM) and iteratively solved by Alternating Direction Implicit (ADI) scheme to obtain temperature and velocity field. The Pressure Weighted Interpolation Method (PWIM) is incorporated to avoid pressure oscillation and allow the use of co-located mesh for fluid flow, making the model computationally efficient. The model is validated for Ti6Al4V and Inconel 718 alloy with the experimental findings from the literature. The obtained results are in good agreement with an average deviation of 5.78% and 20.07% for Ti6Al4V , whereas for Inconel 718, 7.87 and 19.53% for melt-pool depth and width, respectively, were observed. Subsequently, the melt-pool growth and characteristics influenced by various process parameters are also studied.
Semi-analytical formulation for single-track laser powder-bed fusion process to estimate melt-pool characteristics considering fluid-flow and marangoni effect
https://orcid.org/http://orcid.org/0000-0003-2156-4860
The Laser-Based Powder Bed Fusion (LPBF) process is an additive manufacturing (AM) technique used to fabricate intricate 3D metallic components from fine powder particles. This study presents a 2D semi-analytical model, an algorithm developed by incorporating multiple physical phenomena of the process, i.e., heat transfer, fluid flow, and Marangoni effect for computing temperature and velocity distribution, to estimate the melt-pool characteristics for the single-track melting. The laser input energy has been modelled as a moving Gaussian volumetric heat source, and the fluid flow phenomenon has been formulated by ‘Semi-Implicit Method for Pressure Linked Equations’ (SIMPLE) method. A set of two-dimensional transient conservation of mass, momentum, and energy equations are discretized as co-located mesh by Finite Volume Method (FVM) and iteratively solved by Alternating Direction Implicit (ADI) scheme to obtain temperature and velocity field. The Pressure Weighted Interpolation Method (PWIM) is incorporated to avoid pressure oscillation and allow the use of co-located mesh for fluid flow, making the model computationally efficient. The model is validated for Ti6Al4V and Inconel 718 alloy with the experimental findings from the literature. The obtained results are in good agreement with an average deviation of 5.78% and 20.07% for Ti6Al4V , whereas for Inconel 718, 7.87 and 19.53% for melt-pool depth and width, respectively, were observed. Subsequently, the melt-pool growth and characteristics influenced by various process parameters are also studied.
Semi-analytical formulation for single-track laser powder-bed fusion process to estimate melt-pool characteristics considering fluid-flow and marangoni effect
Int J Interact Des Manuf
Bombe, Dattatraya (author) / Kumar, Rakesh (author) / Nandi, Shubhra Kamal (author) / Agrawal, Anupam (author)
2024-09-01
17 pages
Article (Journal)
Electronic Resource
English
LPBF process , Marangoni effect , Finite volume method , Surface tension gradient , Velocity vector Engineering , Engineering, general , Engineering Design , Mechanical Engineering , Computer-Aided Engineering (CAD, CAE) and Design , Electronics and Microelectronics, Instrumentation , Industrial Design
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