Article Influence of recoil pressure, mushy zone flow resistance and reflectivity on melt pool shape in laser powder bed fusion simulation

Jun Katagiri ORCID (Research Center for Structural Materials, National Institute for Materials ScienceROR) ; Masahiro Kusano, SAMURAI ORCID (Research Center for Structural Materials, National Institute for Materials ScienceROR) ; Sukeharu Nomoto SAMURAI ORCID (Research Center for Structural Materials, National Institute for Materials ScienceROR) ; Makoto Watanabe SAMURAI ORCID (Research Center for Structural Materials, National Institute for Materials ScienceROR)

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Jun Katagiri, Masahiro Kusano,, Sukeharu Nomoto, Makoto Watanabe. Influence of recoil pressure, mushy zone flow resistance and reflectivity on melt pool shape in laser powder bed fusion simulation. Case Studies in Thermal Engineering. 2023, 50 (), 103477. https://doi.org/10.1016/j.csite.2023.103477
SAMURAI

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(abstract)

Melt pool dimensions (depth: D and width: W) are strongly correlated with defects generated in laser powder bed fusion. The melt pool dimensions have been evaluated by CFD simulation including solid-liquid-gas phase change and laser multiple reflection. Such a multi-physics simulation requires a large number of parameters. Preliminary simulations for parameter identification require a lot of time and effort. The parameter sensitivity to the melt pool dimensions is important; however, the systematic evaluations have hardly been found in the literature. In this study, we performed systematic parametric evaluation for three parameters related to recoil pressure, flow resistance in solid-liquid mushy zone and Fresnel laser reflection. As a result, the D values increased with increasing recoil pressure, but theW values did not. The flow resistance force influenced the velocities in the mushy zone but not the melt pool dimensions. The D increased with increasing reflectivity, but theW did not. The melt pool dimensions varying recoil pressure, flow resistance force and reflectivity were all inconsistent with the experimental melt pool dimensions. In order to agree with the experimental melt pool dimensions, the problems to be solved were discussed by comparing the previous studies.

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Keyword: Laser powder bed fusion, Multi-physics CFD simulation, Recoil pressure, Mushy zone flow resistance, Fresnel laser reflection model, Melt pool shape

Date published: 2023-09-11

Publisher: Elsevier BV

Journal:

  • Case Studies in Thermal Engineering (ISSN: 2214157X) vol. 50 103477

Funding:

  • the Acquisition, Technology, and Logistics Agency(ATLA) JPJ004596

Manuscript type: Publisher's version (Version of record)

MDR DOI:

First published URL: https://doi.org/10.1016/j.csite.2023.103477

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Updated at: 2024-01-05 22:12:21 +0900

Published on MDR: 2023-10-10 13:44:08 +0900

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