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Simulation of Spot Melting Scan Strategy to Predict Columnar to Equiaxed Transition in Metal Additive Manufacturing
Recently, additive manufacturing (AM) processes are transforming from rapid
prototyping technology to mass industrial production due to increase in the fidelity of the AM
machines. This trend triggers the process optimization for various applications. In prior
literature, high-fidelity numerical models have been presented to understand the rapid
solidification conditions occurring during the process which includes heat transfer, fluid flow
and beam interaction with the raw material. However, most of these models are simulating few
melt passes and it is computationally expensive to simulate an entire layer of the component
being fabricated. In this study, we use a low-fidelity model to simulate an entire layer. We also
introduce a new melt strategy to control the solidification microstructure (i.e. columnar to
equiaxed transition). The response of the solidification morphology to process parameters (ex.
point offset, power, spot time) are investigated in terms of thermal gradient G and solidification
rate R. The model is validated with the experimental microstructure data.Mechanical Engineerin