Numerical Simulation of Direct Metal Laser Sintering of Single-Component Powder on Top of Sintered Layers

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
Bin Xiao ◽  
Yuwen Zhang
Keyword(s):  
Laser Scanning ◽  
Three Dimensional ◽  
Processing Parameters ◽  
Laser Sintering ◽  
Liquid Pool ◽  
Sintering Process ◽  
Direct Metal Laser Sintering ◽  
Three Dimensional Model ◽  
Gaussian Laser Beam ◽  
Scanning Velocity

A three-dimensional model describing melting and resolidification of direct metal laser sintering of loose powders on top of sintered layers with a moving Gaussian laser beam is developed. Natural convection in the liquid pool driven by buoyancy and Marangoni effects is taken into account. A temperature transforming model is employed to model melting and resolidification in the laser sintering process. The continuity, momentum, and energy equations are solved using a finite volume method. The effects of dominant processing parameters including number of the existing sintered layers underneath, laser scanning velocity, and initial porosity on the sintering process are investigated.

Numerical Simulation of Direct Metal Laser Sintering of Single-Component Powder on Top of Sintered Layers

2006 ◽  
Author(s):  
Bin Xiao ◽  
Yuwen Zhang
Keyword(s):  
Laser Scanning ◽  
Three Dimensional ◽  
Processing Parameters ◽  
Laser Sintering ◽  
Liquid Pool ◽  
Sintering Process ◽  
Direct Metal Laser Sintering ◽  
Three Dimensional Model ◽  
Gaussian Laser Beam ◽  
Scanning Velocity

A three dimensional model describing melting and resolidification of direct metal laser sintering of loose powders on top of sintered layers with a moving Gaussian laser beam is developed. Natural convection in the liquid pool driven by buoyancy and Marangoni effects is taken into account. A temperature transforming model is employed to model melting and resolidification in the laser sintering process. The continuity, momentum, and energy equations are solved using a finite volume method. Effects of dominant processing parameters including number of the existing sintered layers underneath, laser scanning velocity and initial porosity on the sintering process are investigated.

Three-Dimensional Modeling of Laser Sintering of a Two-Component Metal Powder Layer on Top of Sintered Layers

2006 ◽  
Vol 129 (3) ◽  
pp. 575-582 ◽  
Author(s):  
Tiebing Chen ◽  
Yuwen Zhang
Keyword(s):  
Metal Powder ◽  
Laser Scanning ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Powder Layer ◽  
Metal Powders ◽  
Three Dimensional Model ◽  
Scanning Velocity ◽  
Laser Beam Intensity ◽  
Two Component

A three-dimensional model of selective laser sintering of a two-component loose metal powder layer on top of previously sintered layers by a single-line laser scanning is presented. A temperature-transforming model is employed to model melting and resolidification accompanied by partial shrinkage during laser sintering. The heat losses at the top surface due to natural convection and radiation are taken into account. The liquid flow of the molten low-melting-point metal powders, which is driven by capillary and gravity forces, is also considered and formulated by using Darcy’s law. The effects of the dominant processing parameters, such as laser-beam intensity, scanning velocity, and number of the existing sintered layers underneath, are investigated.

Three-Dimensional Modeling of Selective Laser Sintering of Two-Component Metal Powder Layers

2005 ◽  
Vol 128 (1) ◽  
pp. 299-306 ◽  
Author(s):  
Tiebing Chen ◽  
Yuwen Zhang
Keyword(s):  
Metal Powder ◽  
Continuous Wave ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Powder Layer ◽  
Metal Powders ◽  
Gaussian Laser Beam ◽  
Scanning Velocity ◽  
Three Dimensional Modeling

Laser sintering of a metal powder mixture that contains two kinds of metal powders with significantly different melting points under a moving Gaussian laser beam is investigated numerically. The continuous-wave laser-induced melting accompanied by shrinkage and resolidification of the metal powder layer are modeled using a temperature-transforming model. The liquid flow of the melted low-melting-point metal driven by capillary and gravity forces is also included in the physical model. The numerical results are validated by experimental results, and a detailed parametric study is performed. The effects of the moving heat source intensity, the scanning velocity, and the thickness of the powder layer on the sintering depth, the configuration of the heat affected zone, and the temperature distribution are discussed.

Microstructure and Tensile Strength of Rapid Manufacturing Parts

2014 ◽  
Vol 903 ◽  
pp. 114-117 ◽  
Author(s):  
Izhar Abd Aziz ◽  
Brian Gabbitas ◽  
Mark Stanford
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Biomedical Applications ◽  
Bulk Material ◽  
Solidification Rate ◽  
Laser Sintering ◽  
Liquid Pool ◽  
Sintering Process ◽  
Direct Metal Laser Sintering ◽  
Production Route

The purpose of this work is to investigate the microstructure and tensile strength of Ti6Al4V pre-alloyed powders produced by a direct metal laser sintering technique. Traditionally, Ti6Al4V products for biomedical applications were produced through hot working or machining of wrought semi-finished products. A change in the production route for manufacturing Ti6Al4V products, from the more traditional methods to an additive manufacturing route, requires an investigation of microstructure and mechanical properties because these are strongly influenced by the production route. The microstructure obtained through rapid solidification during laser sintering shows a very fine α+β lamellar morphology. There is also evidence of martensite which was expected due to high solidification rate of the liquid pool from a temperature above the β-transus during the laser sintering process. Structurally, good mechanical properties which are comparable to the bulk material were obtained.

Analysis and modeling of direct selective laser sintering of two-component metal powders

2005 ◽  
Author(s):  
◽  
Tiebing Chen
Keyword(s):  
Laser Beam ◽  
Selective Laser Sintering ◽  
Finite Thickness ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Powder Layer ◽  
Metal Powders ◽  
Gaussian Laser Beam ◽  
Scanning Velocity ◽  
Two Component

[ACCESS RESTRICTED TO THE UNIVERSITY OF MISSOURI AT AUTHOR'S REQUEST.] Direct Selective Laser Sintering (SLS) is an emerging technology of Solid Freeform Fabrication (SFF) that 3-D parts are built from the metal-based powder bed with CAD data. A one-dimensional analytical model of melting in a two-component powder layer with finite thickness subjected to a constant heat flux heating and a two-dimensional numerical model of SLS of a two-component powder layer with a moving laser beam scanning were developed consecutively. Three-dimensional modeling of laser sintering of a two-component metal powder mixture under a moving Gaussian laser beam was investigated numerically at last. The effects of the moving heat source intensity, the scanning velocity, the thickness of the powder layer and the number of existing sintered layers underneath on the sintering depth, the configuration of the heat affected zone (HAZ) and the temperature distribution are discussed.

Three-Dimensional Sintering of Two-Component Metal Powders With Stationary and Moving Laser Beams

1999 ◽  
Vol 122 (1) ◽  
pp. 150-158 ◽  
Author(s):  
Yuwen Zhang ◽  
A. Faghri ◽  
C. W. Buckley ◽  
T. L. Bergman
Keyword(s):  
Energy Equation ◽  
Three Dimensional ◽  
Steel Powder ◽  
Metal Powders ◽  
Sintering Process ◽  
Gaussian Laser Beam ◽  
Cross Sectional ◽  
Scanning Velocity ◽  
Powder Bed ◽  
Gravity Forces

Melting and resolidification of a mixture of two metal powders with significantly different melting points under irradiation of a stationary or a moving Gaussian laser beam were investigated numerically and experimentally. The liquid motion driven by capillary and gravity forces as well as the shrinkage of the powder bed caused by the overall density change were taken into account in the physical model. The liquid flow was formulated by using Darcy’s law, and the energy equation was given using a temperature transforming model. Prediction were compared with experimental results obtained with nickel braze and AISI 1018 steel powder. The effects of laser properties and the scanning velocity on the laser sintering process were also investigated. An empirical correlation that can be used to predict the cross-sectional area of the heat affected zone is proposed. [S0022-1481(00)70201-5]

Three-Dimensional Modeling of Laser Sintering of a Two-Component Metal Powder Layer on Top of Sintered Layers

2005 ◽  
Author(s):  
Tiebing Chen ◽  
Yuwen Zhang
Keyword(s):  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Processing Parameters ◽  
Laser Sintering ◽  
Powder Layer ◽  
Metal Powders ◽  
Scanning Velocity ◽  
Three Dimensional Modeling ◽  
Sintered Metal ◽  
Gravity Forces

A three-dimensional numerical model of Selective Laser Sintering (SLS) of the metal powders for a single scan line induced by a moving laser beam interacted with a loose powder layer on top of the sintered metal layers is presented. The problem is modeled using a temperature-transforming model and the partial shrinkage induced by melting is accounted for. The heat losses at the top surface due to the natural convection and radiation are taken into account. The liquid flow of the molten low melting point metal powders, which is driven by capillary and gravity forces, is also considered and formulated by using Darcy’s law. The effects of the dominant processing parameters, such as the moving heat source intensity, scanning velocity and number of the existing sintered layers underneath are investigated. A parametric study is performed and the best combination of the processing parameters is recommended.

On three-dimensional printing of 17-4 precipitation-hardenable stainless steel with direct metal laser sintering in aircraft structural applications

2021 ◽  
pp. 146442072110448
Author(s):  
Rupinder Singh ◽  
Rishab ◽  
Jashanpreet S Sidhu
Keyword(s):  
Stainless Steel ◽  
Structural Engineering ◽  
Three Dimensional ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Scanning Speed ◽  
Laser Sintering ◽  
Structural Components ◽  
Direct Metal Laser Sintering ◽  
Structural Applications

The martensitic 17-4 precipitation-hardenable stainless steel is one of the commercially established materials for structural engineering applications in aircrafts due to its superior mechanical and corrosion resistance properties. The mechanical processing of this alloy through a conventional manufacturing route is critical from the dimensional accuracy (Δ d) viewpoint for development of innovative structural components such as: slat tracks, wing flap tracks, etc. In past two decades, a number of studies have been reported on challenges being faced while conventional processing of 17-4 precipitation-hardenable stainless steel for maintaining uniform thickness of aircraft structural components. However, hitherto little has been reported on direct metal laser sintering of 17-4 precipitation-hardenable stainless steel for development of innovative functional prototypes with uniform surface hardness (HV), Δ d, and surface roughness ( Ra) in aircraft structural engineering. This paper reports the effect of direct metal laser sintering process parameters on HV, Δ d, and Ra for structural components. The results of study suggest that optimized settings of direct metal laser sintering from multifactor optimization viewpoint are laser power 100 W, scanning speed 1400 mm/s, and layer thickness 0.02 mm. The results have been supported with scanning electron microscopy analysis (for metallurgical changes such as porosity (%), HV, grain size, etc.) and international tolerance grades for ensuring assembly fitment.

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