scholarly journals Mesoscopic simulation of overlapping behavior in laser powder bed additive manufacturing

2021 ◽  
Author(s):  
Pan Lu ◽  
Liu Tong ◽  
Wang Wen-hao ◽  
Gao Yu ◽  
Zhang Cheng-lin ◽  
...  
Keyword(s):  
Energy Density ◽  
Molten Pool ◽  
Laser Power ◽  
Laser Scanning ◽  
Flow Behavior ◽  
Pure Copper ◽  
Scanning Speed ◽  
Powder Bed ◽  
Volume Energy ◽  
Laser Scanning Speed

Abstract The prediction of the flow behavior of Metal micro-molten pool is prerequisite for high-quality Laser Powder Bed Fusion (L-PBF). In this study, mesoscopic scale numerical simulation modelling for L-PBF process was used to help understand the melting process of pure copper micro-melt pool.In this study, the orthogonal test was designed to study the influence of laser power, laser scanning velocity, hatching space on the flow behavior of molten pool and the overlapping rate of adjacent molten tracks. The results shows that laser scanning speed has the greatest influence on both the size and overlapping rate of the molten pool, and the overall trend was that the size of molten pool continues to increase as the volume energy density increases, and the maximum molten pool size was 243.6um × 110um with volume energy density 370.037 J/mm3, overlapping rate of adjacent molten tracks was 48.84% with volume energy density 285.71 J/mm3. The optimized pure copper laser process parameters were obtained: laser power 300 KW, laser scanning speed 500 mm/s, hatching space 0.07mm, overlapping rate 48.84%.

Research on Microstructure and Wear Property of 45 Steel Quenched with Different Laser Power

2020 ◽  
Vol 861 ◽  
pp. 35-40
Author(s):  
Yu Liu ◽  
Tian Hao Xu ◽  
Ying Liu ◽  
Hai Cheng Zhang ◽  
Xing Xing Li ◽  
...  
Keyword(s):  
Laser Power ◽  
Laser Scanning ◽  
Scanning Speed ◽  
Wear Volume ◽  
Wear Property ◽  
Steel Matrix ◽  
Wear Properties ◽  
Laser Scanning Speed ◽  
Friction And Wear Properties ◽  
Minimum Wear

The surface of 45 steel is quenched by CO2 laser with scanning speed 1000 mm/min and different laser power 1000W, 1200W, 1400W, 1600W and 1800W. Experiments are carried out to analyze microstructure, friction and wear properties of quenched 45 steel. The results show that the quenching layer thickness increases gradually with the increase of laser power,and the maximum value of quenching layer hardness increases first and then decreases. When the laser power is 1600W, the maximum hardness value is 883HV0.5. But when the laser power is 1800W, the hardness of quenching layer becomes to decrease. The reason is the surface of 45 steel becomes to melt. The wear volume increases first and then decreases too. When laser power is 1600W, the minimum wear volume is 0.08mm3, which is 6.4% to the wear volume of 45 steel matrix without laser quenching. Therefore, better microstructure and properties of 45 steel can be obtained when laser scanning speed is 1000mm/min and laser power is 1600W.

scholarly journals In Situ Mo(Si,Al)2-Based Composite through Selective Laser Melting of a MoSi2-30 wt.% AlSi10Mg Mixture

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3720 ◽  
Author(s):  
Tatevik Minasyan ◽  
Sofiya Aydinyan ◽  
Ehsan Toyserkani ◽  
Irina Hussainova
Keyword(s):  
High Temperature ◽  
Selective Laser Melting ◽  
Laser Power ◽  
Laser Scanning ◽  
Scanning Speed ◽  
Laser Melting ◽  
Structural Applications ◽  
Laser Scanning Speed ◽  
Fusion Approach

The laser power bed fusion approach has been successfully employed to manufacture Mo(Si,Al)2-based composites through the selective laser melting of a MoSi2-30 wt.% AlSi10Mg mixture for high-temperature structural applications. Composites were manufactured by leveraging the in situ reaction of the components during printing at 150–300 W laser power, 500–1000 mm·s−1 laser scanning speed, and 100–134 J·mm−3 volumetric energy density. Microcomputed tomography scans indicated a negligible induced porosity throughout the specimens. The fully dense Mo(Si1-x,Alx)2-based composites, with hardness exceeding 545 HV1 and low roughness for both the top (horizontal) and side (vertical) surfaces, demonstrated that laser-based additive manufacturing can be exploited to create unique structures containing hexagonal Mo(Si0.67Al0.33)2.

Influence of Process Parameters on the Mechanical Response of Various Layers Processed Using Direct Metal Laser Sintering (DMLS)

2014 ◽  
Author(s):  
S. Ahmed ◽  
H. Doak ◽  
A. Mian ◽  
R. Srinivasan
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Laser Power ◽  
Laser Scanning ◽  
Mechanical Response ◽  
Scanning Speed ◽  
Direct Metal Laser Sintering ◽  
Influence Of Process Parameters ◽  
Microstructural Morphology ◽  
Laser Scanning Speed

During the DMLS process, sintering of the top layer creates melting and heat affected zone in previously sintered layers. In this paper, we will examine the effects of any given process parameter, such as laser power and laser scanning speed, on the mechanical properties and microstructural morphology within the processed layers.

Numerical simulation and experimental study on laser hardening process of the 42CrMo4 steel

2021 ◽  
Vol 13 (9) ◽  
pp. 168781402110446
Author(s):  
Hongwei Zhang ◽  
Meng Zhu ◽  
Siqi Ji ◽  
Jianjun Zhang ◽  
Hengming Fan
Keyword(s):  
Laser Power ◽  
Laser Scanning ◽  
Scanning Speed ◽  
Element Model ◽  
Laser Hardening ◽  
Hardening Process ◽  
42Crmo4 Steel ◽  
Pitch Bearing ◽  
Laser Scanning Speed ◽  
The Finite Element Model

The large diameter pitch bearing was made of steel 42CrMo4 and the laser hardening process was used to improve its surface properties. In this paper, a numerical approach which can predict the temperature field and the hardened depth is provided for the laser hardening process of the 42CrMo4 steel. According to the simplification of the raceway structure of pitch bearing, the finite element model was constructed using ABAQUS software. Based on the actual process parameters, the transient thermal analysis was accomplished and the distribution of temperature field is analyzed. The hardened depth is determined according to the proposed temperature range. Laser power, laser scanning speed, and spot diameter were considered as input parameters, the experimental studies were performed based on orthogonal design in order to study the effects of process parameters. The finite element model is validated. The surface roughness and microstructure studies on treated surfaces were conducted. Also the micro-hardness testing was performed. The results show that the laser hardening increases surface hardness by about 3.8 times than that of the base material. The three parameters of laser power, laser scanning speed, and spot diameter have a coupling effect on the surface treatment. The input laser power density is more important.

scholarly journals Influence of Pulsed Exposure Strategies on Overhang Structures in Powder Bed Fusion of Ti6Al4V Using Laser Beam

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1125
Author(s):  
Jonas Grünewald ◽  
Pirmin Clarkson ◽  
Ryan Salveson ◽  
Georg Fey ◽  
Katrin Wudy
Keyword(s):  
Surface Roughness ◽  
Energy Density ◽  
Laser Beam ◽  
Continuous Wave ◽  
Scanning Speed ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Volume Energy ◽  
Pulsed Exposure ◽  
Overhang Angle

Manufacturing structures with low overhang angles without support structures is a major challenge in powder bed fusion of metals using laser beam (PBF-LB/M). In the present work, various test specimens and parameter sets with continuous wave (cw) and pulsed exposure are used to investigate whether a reduction of downskin roughness and overhang angle can be achieved in PBF-LB/M of Ti6Al4V. Starting from cw exposure, the limits of overhang angle and surface roughness at the downskin surface are investigated as a reference. Subsequently, the influence of laser power, scanning speed, and hatch distance with fixed pulse duration (τpulse = 25 µs) and repetition rate (υrep = 20 kHz) on surface roughness Ra is investigated. Pulsed exposure strategies enable the manufacturing of flatter overhang angles (≤20° instead of ≥25°). Furthermore, a correlation between the introduced volume energy density and the downskin roughness can be observed for pulsed exposure. As the reduction in volume energy density causes an increase in porosity, the combination of pulsed downskin exposure and commercial cw infill exposure is investigated. The larger the gap in volume energy density between the infill area and downskin area, the more challenging it is combining the two parameter sets. By combining cw infill and pulsed downskin exposure, flatter overhang structures cannot be manufactured, and a reduction in roughness can be achieved.

Effects of Laser Parameters on the Formation of Al2O3-TiC Coating by Laser-Assisted Combustion

2014 ◽  
Vol 597 ◽  
pp. 175-183
Author(s):  
Cai Xuan Lu ◽  
He Ping Li ◽  
Peng Chen ◽  
Li Hong Xue ◽  
You Wei Yan
Keyword(s):  
Laser Processing ◽  
Laser Power ◽  
Laser Scanning ◽  
Nuclear Reactor ◽  
Composite Ceramic ◽  
Scanning Speed ◽  
Combustion Method ◽  
Processing Parameters ◽  
Ceramic Coatings ◽  
Laser Scanning Speed

Nowadays, Al2O3-based ceramic coatings have attracted considerable attention for their potential applications as tritium permeation barrier (TPB) in the nuclear reactor. Herein, dense composite ceramic coatings (Al2O3-TiC) have been successfully fabricated by a facile laser-assisted combustion method. The precursor Al-TiO2-C powder mixture underwent combustion synthesis at high temperatures generated by an incident laser, and Al2O3-TiC coatings were thus obtained. Their crystal structures and morphologies were monitored by x-ray diffraction and field emission scanning electron microscopy. The laser processing parameters, including laser power and laser scanning speed, have been found to play an important role in the microstructure of the products. The optimal laser processing parameters for obtaining Al2O3-TiC coating were 4kW in laser power and 6mm/s in laser scanning speed. The results in this paper may be beneficial to the future study of other coatings fabricated by laser-assisted combustion.

scholarly journals Processability of Atypical WC-Co Composite Feedstock by Laser Powder-Bed Fusion

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 50 ◽  
Author(s):  
Mohaimen Al-Thamir ◽  
D. Graham McCartney ◽  
Marco Simonelli ◽  
Richard Hague ◽  
Adam Clare
Keyword(s):  
Laser Scanning ◽  
Single Layer ◽  
Scanning Speed ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Future Production ◽  
Laser Scanning Speed ◽  
First Time ◽  
Am Processes

Processing of tool materials for cutting applications presents challenges in additive manufacturing (AM). Processes must be carefully managed in order to promote the formation of favourable high-integrity ‘builds’. In this study, for the first time, a satelliting process is used to prepare a WCM-Co (12 wt.% Co) composite. Melting trials were undertaken to evaluate the consolidation behaviour of single tracks within a single layer. Tracks with continuous and relatively uniform surface morphology were obtained. These features are essential for high-quality AM builds in order to encourage good bonding between subsequent tracks within a layer which may reduce porosity within a 3D deposition. This study elucidates the formation of track irregularities, melting modes, crack sensitivity, and balling as a function of laser scanning speed and provides guidelines for future production of WCM-Co by laser powder-bed fusion.

scholarly journals Modeling of Residual Stress Distribution for Components Manufactured by Selective Laser Melting

2019 ◽  
Vol 224 ◽  
pp. 05006
Author(s):  
Tong Ye ◽  
Xiaohui Jiang ◽  
Miaoxian Guo ◽  
Vladimir Kuptsov ◽  
Sergey Fedorov
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Selective Laser Melting ◽  
Laser Power ◽  
Laser Scanning ◽  
Scanning Speed ◽  
Residual Stress Distribution ◽  
Laser Melting ◽  
Laser Scanning Speed ◽  
Formed Part

In this paper, the selective laser melting (SLM) simulation analysis of components is carried out. The residual stress distribution of the formed part was predicted, and the influence of process parameters such as exposure time, laser power and laser scanning speed on the residual stress of the SLM formed part was analyzed. It was found that the residual stress concentration of the formed part was in the middle of the upper surface or the bottom surface. In addition, the laser power and the laser scanning speed have a great influence on the residual stress of the formed part. The results of this study lay a theoretical and experimental basis for the optimization of residual stress and quality control of SLM components.

Laser Cladding In Situ Tungsten Carbide Reinforced Ferrous Matrix Surface Composites

2011 ◽  
Vol 189-193 ◽  
pp. 771-776 ◽  
Author(s):  
Ying Ying Chen ◽  
Wen Ge Li
Keyword(s):  
Tungsten Carbide ◽  
Laser Cladding ◽  
Laser Power ◽  
Laser Scanning ◽  
Synthesis Method ◽  
Scanning Speed ◽  
Hardness Measurement ◽  
Element Distribution ◽  
Matrix Surface ◽  
Laser Scanning Speed

Tungsten carbide cermets coating on carbon steel were fabricated by laser clad cooperation combustion synthesis method. The microstructure, phase, element distribution and microhardness have been analyzed with the aid of SEM, XRD, EDS, EPMA and microhardness-tester. It is shown that the coating consisted of WC, CW3, W2C, WCx, and FeNi3. The results of hardness measurement showed that the hardness was superior to substrate. Analyze the effect of different laser power and different laser scanning speed on the quality of the laser cladding surface, the surface quality gets better with the increasing of the laser power, and gets better with the reducing of the scanning speed.

scholarly journals Spatter Formation and Splashing Induced Defects in Laser-Based Powder Bed Fusion of AlSi10Mg Alloy: A Novel Hydrodynamics Modelling with Empirical Testing

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 2023
Author(s):  
Asif Ur Rehman ◽  
Muhammad Arif Mahmood ◽  
Peyman Ansari ◽  
Fatih Pitir ◽  
Metin Uymaz Salamci ◽  
...  
Keyword(s):  
High Speed ◽  
Laser Scanning ◽  
Scanning Speed ◽  
Operating Conditions ◽  
Powder Layer ◽  
Hydraulic Pressure ◽  
Powder Bed ◽  
Vapor Cloud ◽  
Laser Scanning Speed ◽  
Material Interaction

Powder spattering and splashing in the melt pool are common phenomena during Laser-based Powder Bed Fusion (LPBF) of metallic materials having high fluidity. For this purpose, analytical and computational fluid dynamics (CFD) models have been deduced for the LPBF of AlSi10Mg alloy. The single printed layer’s dimensions were estimated using primary operating conditions for the analytical model. In CFD modelling, the volume of fluid and discrete element modelling techniques were applied to illustrate the splashing and spatter phenomena, providing a novel hydrodynamics CFD model for LPBF of AlSi10Mg alloy. The computational results were compared with the experimental analyses. A trial-and-error method was used to propose an optimized set of parameters for the LPBF of AlSi10Mg alloy. Laser scanning speed, laser spot diameter and laser power were changed. On the other hand, the powder layer thickness and hatch distance were kept constant. Following on, 20 samples were fabricated using the LPBF process. The printed samples’ microstructures were used to select optimized parameters for achieving defect-free parts. It was found that the recoil pressure, vaporization, high-speed vapor cloud, Marangoni flow, hydraulic pressure and buoyancy are all controlled by the laser-material interaction time. As the laser-AlSi10Mg material interaction period progresses, the forces presented above become dominant. Splashing occurs due to a combination of increased recoil pressure, laser-material interaction time, higher material’s fluidity, vaporization, dominancy of Marangoni flow, high-speed vapor cloud, hydraulic pressure, buoyancy, and transformation of keyhole from J-shape to reverse triangle-shape that is a tongue-like protrusion in the keyhole. In the LPBF of AlSi10Mg alloy, only the conduction mode melt flow has been determined. For multi-layers printing of AlSi10Mg alloy, the optimum operating conditions are laser power = 140 W, laser spot diameter = 180 µm, laser scanning speed = 0.6 m/s, powder layer thickness = 50 µm and hatch distance = 112 µm. These conditions have been identified using sample microstructures.

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