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Optimization of Surface Roughness and Density of Overhang Structures Fabricated by Laser Powder Bed Fusion.

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Coupled Computational Fluid Dynamics-Discrete Element Method Model for Investigation of Powder Effects in

Trong-Nhan Le1,2, Yu-Lung Lo1,3, Wei Hung1

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Summary

This study uses a 3D simulation to explore how chamber pressure and gravity affect metal vapor spouting in laser powder bed fusion (L-PBF). Adjusting gravity effectively reduces spatter and powder bed denudation during L-PBF.

Keywords:
CFD-DEM coupled modelchamber pressuredenudationgravitational forcelaser powder bed fusionpowder entrainment

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Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Computational Modeling

Background:

  • Laser Powder Bed Fusion (L-PBF) is an advanced additive manufacturing technique.
  • Metal vapor spouting during L-PBF can lead to defects like spatter and powder bed denudation.
  • Controlling these defects is crucial for improving part quality and process reliability.

Purpose of the Study:

  • To develop and utilize a 3D computational fluid dynamics-discrete element method (CFD-DEM) coupled simulation model.
  • To investigate the particle dynamics of SS316L metal vapor spouting during single-scan-track L-PBF.
  • To examine the influence of nonconventional process variables, specifically chamber pressure and gravitational force, on spatter and denudation suppression.

Main Methods:

  • Implementation of a comprehensive 3D CFD-DEM coupled simulation model.
  • Simulation of SS316L metal vapor spouting dynamics under varying chamber pressures and gravitational forces.
  • Analysis of particle behavior to quantify spatter formation and powder bed denudation.

Main Results:

  • Adjusting gravitational force was found to be an effective method for suppressing both spatter formation and powder bed denudation.
  • Chamber pressure exhibited a marginal effect on the denudation phenomenon.
  • Higher chamber pressure promoted upward metal vapor spouting, while lower pressure resulted in more radial distribution.

Conclusions:

  • Both chamber pressure and gravitational force show potential as feasible approaches for suppressing spattering and denudation phenomena in L-PBF.
  • These findings are particularly relevant for the L-PBF processing of light-weight materials.
  • The developed CFD-DEM model provides a valuable tool for optimizing L-PBF process parameters.