94 research outputs found
Powder Bed Layer Characteristics: The Overseen First-Order Process Input
A discrete element powder model is used in conjunction with a finite volume melting model on the first layer of a powder bed selective laser melting process
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Computational Modelling and Experimental Validation of Single In625 Line Tracks in Laser Powder Bed Fusion
Laser track experiments are performed using INCONEL® nickel-based powder alloy,
IN625, in a Powder Bed Fusion (PBF) system. Optical microscopy is used to obtain key track
dimensions and morphology for various machine parameters, allowing direct validation of ESI
Group’s ICME suite of tools for modelling AM. The high-fidelity powder bed model simulates
the melt pool formation based on solution of the Navier-Stokes equations and heat transfer,
radiative powder-laser interaction, phase change, surface tension, Marangoni forces and recoil
pressure. Models are enhanced by measured thermophysical material properties. Validation of
the solidified melt geometry showing that conductive mode melting and instabilities such as
balling can be captured with existing models and pave the way for models which capture the
onset of keyholing. Examination of the melt track microstructures can also be used to determine
local cooling rates, granting insight into the phase evolution differences between the alloys.Mechanical Engineerin
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