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Heat Source Modeling in Selective Laser Melting.

Elham Mirkoohi1, Daniel E Seivers2, Hamid Garmestani3

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Summary

This study introduces five analytical heat source models to predict temperature fields in selective laser melting (SLM), a metal additive manufacturing process. The models account for temperature-dependent properties and multi-layer effects, validated by experimental melt pool data.

Keywords:
additive manufacturingheat source modelingselective laser meltingtemperature field

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Area of Science:

  • Materials Science and Engineering
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • Selective laser melting (SLM) is an advanced additive manufacturing (AM) technique for creating intricate metal parts layer by layer using a laser.
  • Accurate prediction of the temperature field during SLM is critical for controlling molten pool dimensions, thermal stresses, and dimensional accuracy.
  • Understanding laser-matter interaction and its thermal effects is fundamental to optimizing the SLM process.

Purpose of the Study:

  • To develop and present five analytical heat source models for predicting the three-dimensional temperature field in selective laser melting.
  • To investigate the influence of temperature-sensitive material properties and latent heat of melting on the thermal behavior.
  • To incorporate the multi-layer aspect of AM by considering the thermal history from previous layers.

Main Methods:

  • Introduced five distinct heat source models: steady state moving point, transient moving point, semi-elliptical, double elliptical, and uniform moving heat sources.
  • Solved the three-dimensional heat conduction differential equations using separation of variables and Green's functions.
  • Incorporated temperature-dependent thermal properties and latent heat of melting to account for material phase changes and thermal gradients.

Main Results:

  • Developed validated analytical models for predicting temperature fields in SLM, considering complex thermal phenomena.
  • The models were validated against experimental measurements of melt pool geometry, demonstrating good agreement.
  • Analysis provided insights into the effect of process parameters on the balling effect in metal AM.

Conclusions:

  • The proposed analytical heat source models offer a robust framework for understanding and predicting thermal behavior in selective laser melting.
  • Accurate thermal modeling is essential for controlling part quality, minimizing defects, and optimizing process parameters in metal AM.
  • Further research can leverage these models to enhance the dimensional accuracy and reduce residual stresses in SLM-fabricated parts.