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 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.

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 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.

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

2005 ◽  
Author(s):  
Tiebing Chen ◽  
Yuwen Zhang
Keyword(s):  
Laser Beam ◽  
Metal Powder ◽  
Scanning Speed ◽  
Processing Parameters ◽  
Powder Layer ◽  
Metal Powders ◽  
Gaussian Laser Beam ◽  
Laser Beam Intensity ◽  
Multiple Line ◽  
Two Component

Multiple line laser scan sintering of a two-component metal powder layer on top of the sintered layers with a moving circular Gaussian laser beam is modeled numerically. The overlap between the adjacent scan lines to achieve enhanced bonding is taken into account. The binding between the newly sintered layer and existing sintered layers underneath through melting is also considered. The governing equation is formulated by a temperature-transforming model with partial shrinkage induced by melting considered. The liquid flow of the molten low melting point metal powders, which is driven by capillary and gravity forces, is formulated by Darcy’s law. The effects of the dominant processing parameters, including the moving laser beam intensity, scanning speed and number of the existing sintered layers underneath, on the shape of the heat affected zone (HAZ) are investigated. A parametric study is performed and the best combination of the processing parameters is recommended.

Analysis of Melting in a Mixed Metal Powder Bed With Finite Thickness Subjected to Constant Heat Flux Heating

2003 ◽  
Author(s):  
Tiebing Chen ◽  
Yuwen Zhang
Keyword(s):  
Selective Laser Sintering ◽  
Finite Thickness ◽  
Three Dimensional ◽  
Constant Heat Flux ◽  
Metal Powders ◽  
Powder Bed ◽  
Solid Foundation ◽  
Solid Liquid Interface ◽  
Solid Liquid ◽  
Liquid And Solid Phases

Melting of a subcooled powder bed with the finite thickness that contains a mixture of two metal powders with significantly different melting points is investigated analytically. Shrinkage induced by melting is taken into account in the physical model. The temperature distributions in the liquid and solid phases were obtained using an exact solution and an integral approximate solution, respectively. The effects of porosity, Stefan number, and subcooling on the surface temperature and solid-liquid interface are also investigated. The present work built solid foundation to investigate the complex three-dimensional selective laser sintering (SLS) process.

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.

scholarly journals Direct selective laser sintering and melting of ceramics: a review

2017 ◽  
Vol 23 (3) ◽  
pp. 611-623 ◽  
Author(s):  
Swee Leong Sing ◽  
Wai Yee Yeong ◽  
Florencia Edith Wiria ◽  
Bee Yen Tay ◽  
Ziqiang Zhao ◽  
...  
Keyword(s):  
Laser Beam ◽  
Selective Laser Sintering ◽  
Ceramic Powder ◽  
Ceramic Materials ◽  
High Energy ◽  
Laser Sintering ◽  
Powder Layer ◽  
Full Density ◽  
Content Type ◽  
Direct Laser

Purpose This paper aims to provide a review on the process of additive manufacturing of ceramic materials, focusing on partial and full melting of ceramic powder by a high-energy laser beam without the use of binders. Design/methodology/approach Selective laser sintering or melting (SLS/SLM) techniques are first introduced, followed by analysis of results from silica (SiO2), zirconia (ZrO2) and ceramic-reinforced metal matrix composites processed by direct laser sintering and melting. Findings At the current state of technology, it is still a challenge to fabricate dense ceramic components directly using SLS/SLM. Critical challenges encountered during direct laser melting of ceramic will be discussed, including deposition of ceramic powder layer, interaction between laser and powder particles, dynamic melting and consolidation mechanism of the process and the presence of residual stresses in ceramics processed via SLS/SLM. Originality/value Despite the challenges, SLS/SLM still has the potential in fabrication of ceramics. Additional research is needed to understand and establish the optimal interaction between the laser beam and ceramic powder bed for full density part fabrication. Looking into the future, other melting-based techniques for ceramic and composites are presented, along with their potential applications.

Selective laser sintering of single‐ and two‐component metal powders

2003 ◽  
Vol 9 (2) ◽  
pp. 68-78 ◽  
Author(s):  
Nikolay Tolochko ◽  
Sregei Mozzharov ◽  
Tahar Laoui ◽  
Ludo Froyen
Keyword(s):  
Selective Laser Sintering ◽  
Laser Sintering ◽  
Metal Powders ◽  
Two Component
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