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Virtual Development of Process Parameters for Bulk Metallic Glass Formation in Laser-Based Powder Bed Fusion.

Johan Lindwall1, Andreas Lundbäck1, Jithin James Marattukalam2

  • 1Department of Engineering Sciences and Mathematics, Solid Mechanics, Luleå University of Technology, 97187 Lulea, Sweden.

Materials (Basel, Switzerland)
|January 21, 2022
PubMed
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Developing bulk metallic glass via additive manufacturing is optimized by a new simulation method. This approach predicts how process parameters like laser power and hatch spacing influence crystalline phase formation, reducing costly trial-and-error experiments.

Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Computational Materials Science

Background:

  • Additive manufacturing (AM) of bulk metallic glasses (BMGs) requires extensive parameter optimization, involving costly and time-consuming experimental trials.
  • Evaluating BMG phase structure typically necessitates destructive testing, adding to the expense and complexity of process development.
  • Existing methods for BMG formation lack efficient predictive tools for process parameter influence.

Purpose of the Study:

  • To present a computational modeling method for predicting crystalline phase evolution during laser-based powder bed fusion (PBF-LB) of BMGs.
  • To investigate the impact of key process parameters—laser power, hatch spacing, and hatch length—on glass formation.
  • To offer a complementary tool for optimizing AM process parameters and scanning strategies for BMGs.
Keywords:
additive manufacturingclassical nucleation and growth theorycrystallisation in metallic glassmetallic glasssimulation of laser-based powder bed fusion

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Main Methods:

  • Utilized numerical simulations to model the influence of varying laser power, hatch spacing, and hatch length on crystalline phase evolution.
  • Performed simulations for scanning five consecutive layers to assess microstructural changes.
  • Compared simulation results (crystalline volume fraction, crystal number density, mean crystal radius) with experimental trends.

Main Results:

  • Simulation results demonstrated a trend consistent with experimental estimates for crystalline phase fraction.
  • Identified that low laser power, large hatch spacing, and long hatch lengths are favorable for BMG formation in PBF-LB.
  • Observed an offset in absolute values, with the numerical model over-predicting crystalline phases, indicating areas for model refinement.

Conclusions:

  • The developed modeling approach effectively predicts trends in crystalline phase evolution during PBF-LB for BMGs.
  • The simulation method can guide the selection of favorable process parameters and scanning strategies, reducing experimental effort.
  • This predictive tool serves as a valuable complement to experimental methods in the development of AM for BMGs.