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Finite Element Analysis of Melt Pool Characteristics in Selective Laser Spot Melting on a Powder Layer

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3D Printing and Additive Manufacturing Technologies

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Abstract

In this work, volume contraction of powder layer and convective flow in the melt pool during laser spot melting of Ti–6Al–4V powder layer are investigated using a transient two-dimensional finite element model. An algorithm, coupled with the finite element model, accounting for volume contraction due to melting of porous powder to a denser liquid is proposed, which is thereafter used to understand the role of natural and Marangoni convection on the melt pool behaviour. Results for the melt pool characteristics, such as melt pool geometry, melt pool fluid flow dynamics and thermal behaviour are presented.

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Abbreviations

C p :

Specific heat capacity (J kg−1 K−1)

g :

Acceleration due to gravity (m s−2)

K :

Thermal conductivity (W m−1 K−1)

L :

Latent heat of fusion (J kg−1)

T :

Temperature (K)

\( \vec{u} \) :

Velocity vector (m s−1)

φ :

Porosity

P laser :

Laser power (W)

v g :

Velocity magnitude of Gaussian profile (m s−1)

k powder :

Thermal conductivity of powder layer (W m−1 K−1)

k solid :

Thermal conductivity of substrate (W m−1 K−1)

R :

Gaussian beam spot size (m)

h c :

Heat convection coefficient (W m2 K−1)

β T :

Coefficient of thermal expansion (K−1)

T solidus :

Solidus temperature (K)

T liquidus :

Liquidus temperature (K)

μ :

Dynamic viscosity (kg m−1 s−1)

ρ :

Density (kg m−3)

γ :

Surface tension (N m−1)

σ :

Stefan–Boltzmann constant (W m2 K−4)

solidus:

Solidus temperature

liquidus:

Liquidus temperature

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur, 208016, India

    Akash Aggarwal & Arvind Kumar

Authors
  1. Akash Aggarwal
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  2. Arvind Kumar
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Correspondence to Arvind Kumar .

Editor information

Editors and Affiliations

  1. Additive Manufacturing Society of India, Bengaluru, Karnataka, India

    L. Jyothish Kumar

  2. Department of Mechanical Engineering, Indian Institute of Technology Delhi, New Delhi, India

    Pulak M. Pandey

  3. Component Technology, The Manufacturing Technology Centre, Coventry, Warwickshire, United Kingdom

    David Ian Wimpenny

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Aggarwal, A., Kumar, A. (2019). Finite Element Analysis of Melt Pool Characteristics in Selective Laser Spot Melting on a Powder Layer. In: Kumar, L., Pandey, P., Wimpenny, D. (eds) 3D Printing and Additive Manufacturing Technologies. Springer, Singapore. https://doi.org/10.1007/978-981-13-0305-0_1

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  • DOI: https://doi.org/10.1007/978-981-13-0305-0_1

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  • Publisher Name: Springer, Singapore

  • Print ISBN: 978-981-13-0304-3

  • Online ISBN: 978-981-13-0305-0

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