Prediction of Upper Surface Roughness in Laser Powder Bed Fusion

In this study, a physics-based analytical method was proposed for the prediction of upper surface roughness in laser powder bed fusion (LPBF). The temperature distribution and molten pool shape in the melting process were first predicted by an analytical thermal model. The cap area of the solidified molten pool was assumed to be half-elliptical. Based on this assumption and the principle of mass conservation, the cap height and the specific profile of the cap area were obtained. The transverse overlapping pattern of adjacent molten pools of upper layer was then obtained, with given hatch space. The analytical expression of the top surface profile was obtained after putting this overlapping pattern into a 2D coordinate system. The expression of surface roughness was then derived as an explicit function of the process parameters and material properties, based on the definition of surface roughness (Ra) in the sense of an arithmetic average. The predictions of surface roughness were then compared with experimental measurements of 316L stainless steel for validation and show acceptable agreement. In addition, the proposed model does not rely on numerical iterations, which ensures its low computational cost. Thus, the proposed analytical method can help understand the causes for roughness in LPBF and guide the optimization of process conditions to fabricate products with good quality. The sensitivity of surface roughness to process conditions was also investigated in this study.

Analytical Prediction of Balling, Lack-of-Fusion and Keyholing Thresholds in Powder Bed Fusion

This paper proposes analytical modeling methods for the prediction of balling, lack-of-fusion and keyholing thresholds in the laser powder bed fusion (LPBF) additive manufacturing. The molten pool dimensions were first predicted by a closed-form analytical thermal model. The effects of laser power input, boundary heat loss, powder size distribution and powder packing pattern were considered in the calculation process. The predicted molten pool dimensions were then employed in the calculation of analytical thresholds for these defects. Reported experimental data with different materials were compared to predictions to validate the presented analytical models. The predicted thresholds of these defects under various process conditions have good agreement with the experimental results. The computation time for the presented models is less than 5 min on a personal computer. The optimized process window for Ti6Al4V was obtained based on the analytical predictions of these defects. The sensitivity analyses of the value of threshold to the laser power and scanning speed were also conducted. The proposed analytical methods show higher computational efficiency than finite element methods, without including any iteration-based computations. The acceptable predictive accuracy and low computational time will make the proposed analytical strategy be a good tool for the optimization of process conditions for the fabrication of defects-free complex products in laser powder bed fusion.

Thermal Properties and Behaviour of Am-Bearing Fuel in European Space Radioisotope Power Systems

The European Space Agency is funding the research and development of 241Am-bearing oxide-fuelled radioisotope power systems (RPSs) including radioisotope thermoelectric generators (RTGs) and European Large Heat Sources (ELHSs). The RPSs’ requirements include that the fuel’s maximum temperature, Tmax, must remain below its melting temperature. The current prospected fuel is (Am0.80U0.12Np0.06Pu0.02)O1.8. The fuel’s experimental heat capacity, Cp, is determined between 20 K and 1786 K based on direct low temperature heat capacity measurements and high temperature drop calorimetry measurements. The recommended high temperature equation is Cp(T/K) = 55.1189 + 3.46216 × 102 T − 4.58312 × 105 T−2 (valid up to 1786 K). The RTG/ELHS Tmax is estimated as a function of the fuel thermal conductivity, k, and the clad’s inner surface temperature, Ti cl, using a new analytical thermal model. Estimated bounds, based on conduction-only and radiation-only conditions between the fuel and clad, are established. Estimates for k (80–100% T.D.) are made using Cp, and estimates of thermal diffusivity and thermal expansion estimates of americium/uranium oxides. The lowest melting temperature of americium/uranium oxides is assumed. The lowest k estimates are assumed (80% T.D.). The highest estimated Tmax for a ‘standard operating’ RTG is 1120 K. A hypothetical scenario is investigated: an ELHS Ti cl = 1973K-the RPSs’ requirements’ maximum permitted temperature. Fuel melting will not occur.

A printability assessment framework for fabricating low variability nickel-niobium parts using laser powder bed fusion additive manufacturing

Purpose There is recent emphasis on designing new materials and alloys specifically for metal additive manufacturing (AM) processes, in contrast to AM of existing alloys that were developed for other traditional manufacturing methods involving considerably different physics. Process optimization to determine processing recipes for newly developed materials is expensive and time-consuming. The purpose of the current work is to use a systematic printability assessment framework developed by the co-authors to determine windows of processing parameters to print defect-free parts from a binary nickel-niobium alloy (NiNb5) using laser powder bed fusion (LPBF) metal AM. Design/methodology/approach The printability assessment framework integrates analytical thermal modeling, uncertainty quantification and experimental characterization to determine processing windows for NiNb5 in an accelerated fashion. Test coupons and mechanical test samples were fabricated on a ProX 200 commercial LPBF system. A series of density, microstructure and mechanical property characterization was conducted to validate the proposed framework. Findings Near fully-dense parts with more than 99% density were successfully printed using the proposed framework. Furthermore, the mechanical properties of as-printed parts showed low variability, good tensile strength of up to 662 MPa and tensile ductility 51% higher than what has been reported in the literature. Originality/value Although many literature studies investigate process optimization for metal AM, there is a lack of a systematic printability assessment framework to determine manufacturing process parameters for newly designed AM materials in an accelerated fashion. Moreover, the majority of existing process optimization approaches involve either time- and cost-intensive experimental campaigns or require the use of proprietary computational materials codes. Through the use of a readily accessible analytical thermal model coupled with statistical calibration and uncertainty quantification techniques, the proposed framework achieves both efficiency and accessibility to the user. Furthermore, this study demonstrates that following this framework results in printed parts with low degrees of variability in their mechanical properties.

An analytical thermal model of a railway vehicle brake shoe

Estimation of temperature distribution in brake shoes is very important in order to prevent thermal damages such as cracks, fading etc. In this research, the thermal model of brake shoe in a train is introduced considering time-dependent frictional heat load in two modes of emergency and continuous braking. The governing heat conduction equation is solved in polar coordinate by using the method of separation of variables combined with Duhamel integral and a closed-form solution is introduced. Results show the good ability of analytical solution to estimate exact temperature profile in composite and cast iron brake shoes. The ability of the solution for estimation of braking situation to prevent from melting criteria is demonstrated. The composite brake shoe will reach to the melting point of 590 °C in continuous braking at the speed of about 120 km/h and the fading limit in cast iron shoe is occurred after 8 sec in emergency braking mode. The introduced thermal model can be applied as a verification branch of other works and can reduced the huge costs of experimental tests of brake shoes.

A Semi-Analytical Solution for Temperature Distribution in Friction Stir Welding

In this paper, a semi-analytical thermal model of friction stir welding processes is developed in which the heat-generating regions are divided into many elements as point heat sources. The heat generation in each element involves the friction and plastic deformation, and the temperature rise caused by each element is calculated by solving the heat conduction equation of a moving heat source in a solid body. The heat loss through the top and bottom surfaces are considered in the model as heat sinks. The asymmetric distribution of the temperature is calculated through the whole process and over the whole volume of the workpiece by integrating the effects of all heat sources and sinks. The temperature-dependent material properties are updated by a numerical routine. The comparison between the calculated results and the experimental data clearly approved the validity of the proposed method for some aluminum and steel alloys.