Numerical Study of Grain Growth in Laser Powder Bed Fusion Additive Manufacturing of Metals

2021 ◽  
pp. 2141012
Author(s):  
Zhida Huang ◽  
Zongyue Fan ◽  
Hao Wang ◽  
Bo Li
Keyword(s):  
Heat Transfer ◽  
Additive Manufacturing ◽  
Grain Growth ◽  
Phase Field ◽  
Field Calculation ◽  
Computational Domain ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Cooling Process ◽  
Powder Bed

Laser Powder Bed Fusion (LPBF) is an additive manufacturing method that manufactures high density and quality metal products. We present a coupled grain growth and heat transfer modeling technique to understand the materials microstructure evolution in metals during the cooling process of LPBF. The phase-field model is combined with a transient heat transfer equation to simulate the solidification and crystallization of the melt pool simultaneously. Specifically, the variable domain and driving force of the order parameters in the phase-field calculation are defined using current temperature distribution. Additionally, the latent heat generated by crystallization is introduced as a heat source to affect temperature evolution in the cooling process. The finite element method with a staggering strategy is employed to solve the coupled governing equations on an irregular computational domain. The computational framework is verified in a one-dimensional solidification problem by comparing the velocity of the fluid-solid interface. The two-way coupling solution of solidification and crystallization is studied in an example of LPBF of Aluminum alloys.

scholarly journals GEOMETRICAL BENCHMARKING OF LASER POWDER BED FUSION SYSTEMS BASED ON DESIGNER NEEDS

2021 ◽  
Vol 1 ◽  
pp. 1657-1666
Author(s):  
Joaquin Montero ◽  
Sebastian Weber ◽  
Christoph Petroll ◽  
Stefan Brenner ◽  
Matthias Bleckmann ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Use Case ◽  
Powder Bed Fusion ◽  
Design For Additive Manufacturing ◽  
Laser Powder Bed Fusion ◽  
Measuring Systems ◽  
Powder Bed ◽  
Geometric Dimensioning And Tolerancing ◽  
Uncertainty Map ◽  
New System

AbstractCommercially available metal Laser Powder Bed Fusion (L-PBF) systems are steadily evolving. Thus, design limitations narrow and the diversity of achievable geometries widens. This progress leads researchers to create innovative benchmarks to understand the new system capabilities. Thereby, designers can update their knowledge base in design for additive manufacturing (DfAM). To date, there are plenty of geometrical benchmarks that seek to develop generic test artefacts. Still, they are often complex to measure, and the information they deliver may not be relevant to some designers. This article proposes a geometrical benchmarking approach for metal L-PBF systems based on the designer needs. Furthermore, Geometric Dimensioning and Tolerancing (GD&T) characteristics enhance the approach. A practical use-case is presented, consisting of developing, manufacturing, and measuring a meaningful and straightforward geometric test artefact. Moreover, optical measuring systems are used to create a tailored uncertainty map for benchmarking two different L-PBF systems.

scholarly journals Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 422
Author(s):  
Dana Ashkenazi ◽  
Alexandra Inberg ◽  
Yosi Shacham-Diamand ◽  
Adin Stern
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Ion Beam ◽  
Surface Finishing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Finishing Process ◽  
Gold Silver ◽  
3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

scholarly journals Laser powder bed fusion additive manufacturing of highly conductive parts made of optically absorptive carburized CuCr1 powder

2021 ◽  
Vol 198 ◽  
pp. 109369
Author(s):  
Suraj Dinkar Jadhav ◽  
Pushkar Prakash Dhekne ◽  
Etienne Brodu ◽  
Brecht Van Hooreweder ◽  
Sasan Dadbakhsh ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed
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