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Related Experiment Video

Updated: Aug 22, 2025

Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition
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Numerical Simulation in the Melt Pool Evolution of Laser Powder Bed Fusion Process for Ti6Al4V.

Yixuan Xu1,2, Dongyun Zhang1,2, Junyuan Deng1,2

  • 1Institute of Laser Engineering, Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China.

Materials (Basel, Switzerland)
|November 11, 2022
PubMed
Summary

This study developed a physical model using the Volume of Fluid (VOF) method to simulate melt pool dynamics in laser powder bed fusion (L-PBF). The model reveals how laser parameters affect melt pool evolution and surface morphology, crucial for optimizing Ti6Al4V processing.

Keywords:
Ti6Al4Vfluid flowlaser powder bed fusion (L-PBF) processmelt pool evolutionnumerical simulationtemperature distribution

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Area of Science:

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

Background:

  • Understanding melt pool dynamics is critical for controlling the quality of parts produced by laser powder bed fusion (L-PBF).
  • The free interface behavior of gas and liquid phases, along with fluid flow, significantly impacts melt pool evolution and final surface morphology.
  • Accurate physical modeling is needed to predict and optimize L-PBF processes.

Purpose of the Study:

  • To develop and validate a physical model for tracking the free interface of the melt pool during L-PBF.
  • To investigate the influence of process parameters on melt pool evolution, fluid flow, and surface morphology.
  • To analyze the temperature distribution and fluid flow within the melt pool for better understanding of Ti6Al4V L-PBF.

Main Methods:

  • A physical model was developed using the Volume of Fluid (VOF) method.
  • The model incorporates a combined heat source (parabolic rotation and cylindrical distribution) and a stochastic powder bed model.
  • Simulations focused on the first and second laser scanning tracks to analyze melt pool behavior.

Main Results:

  • Process parameters like laser power and scanning speed significantly affect melt pool fluid flow and surface morphology.
  • The second laser track exhibited larger melt pool geometry, higher temperatures, and faster fluid flow compared to the first track.
  • Smoother surface morphology was more easily achieved on the second track due to increased space for metal flow.

Conclusions:

  • The developed VOF model accurately predicts melt pool behavior and is in good agreement with experimental results.
  • Understanding melt pool temperature fluctuations and fluid flow dynamics is key to analyzing and regulating the L-PBF process for Ti6Al4V.
  • The findings provide insights for optimizing L-PBF process parameters to achieve desired part quality and surface finish.