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Thermal dynamic behavior during selective laser melting of K418 superalloy: numerical simulation and experimental verification

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Abstract

During selective laser melting (SLM) of K418 powder, the influence of the process parameters, such as laser power P and scanning speed v, on the dynamic thermal behavior and morphology of the melted tracks was investigated numerically. A 3D finite difference method was established to predict the dynamic thermal behavior and flow mechanism of K418 powder irradiated by a Gaussian laser beam. A three-dimensional randomly packed powder bed composed of spherical particles was established by discrete element method. The powder particle information including particle size distribution and packing density were taken into account. The volume shrinkage and temperature-dependent thermophysical parameters such as thermal conductivity, specific heat, and other physical properties were also considered. The volume of fluid method was applied to reconstruct the free surface of the molten pool during SLM. The geometrical features, continuity boundaries, and irregularities of the molten pool were proved to be largely determined by the laser energy density. The numerical results are in good agreement with the experiments, which prove to be reasonable and effective. The results provide us some in-depth insight into the complex physical behavior during SLM and guide the optimization of process parameters.

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Acknowledgements

The research is financially supported by Science Challenge Project of China, Dongguan University of Technology high-level talents (innovation team) research project (project number: KCYCXPT2016003), National Natural Science Foundation of China under Grant No. 51775420, and Science and Technology Planning Project of Guangdong Province Grant No. 2017B09091101.

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Author notes

  1. Zhen Chen and Yu Xiang contributed equally to this work and should be considered co-first authors.

Authors and Affiliations

  1. State Key Laboratory of Manufacturing System Engineering, Xi’an Jiaotong University, Xi’an, 710049, Shaanxi, China

    Zhen Chen, Yu Xiang, Zhengying Wei, Pei Wei, Bingheng Lu & Jun Du

  2. School of Mechanical Engineering, Dongguan University of Technology, Dongguan, 523808, China

    Bingheng Lu

  3. Xi’an National Institute of Additive Manufacturing Co., Ltd., Xi’an, 710300, Shaanxi, China

    Lijuan Zhang

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  1. Zhen Chen
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Correspondence to Zhen Chen.

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Chen, Z., Xiang, Y., Wei, Z. et al. Thermal dynamic behavior during selective laser melting of K418 superalloy: numerical simulation and experimental verification. Appl. Phys. A 124, 313 (2018). https://doi.org/10.1007/s00339-018-1737-8

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