Simulation of Laser Beam Melting of Steel Powders using the Three-Dimensional Volume of Fluid Method

By Franz-Josef Gürtler, Michael Cornelius Hermann Karg, Karl-Heinz Leitz, Michael Schmidt. 2013

169 citations recorded by the source corpus.

Abstract A transient three-dimensional beam-matter-interaction model was developed to simulate the process dynamics of laser beam melting (LBM) of metals in the powder bed. The simulations were realized by the software OpenFOAM and modified solvers. Based on the continuity equation, the equation of heat conduction and the Navier-Stokes equation the laser material interaction is described. Furthermore, the volume of fluid method is used to characterize the free surfaces of the multi-phase system. These process simulations were performed for steel powders. The parameters were chosen according to those applied in industrial machines and the simulation results show good correlation to experimental data.

Subfields: Computational Mechanics, Mechanical Engineering, Mechanics of Materials

View Paper: https://www.semanticscholar.org/paper/85e3d2ae6a68b6cab386ba8373025e69c691e8bb

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In Computational Mechanics

In Mechanical Engineering

In Mechanics of Materials

Citations in the corpus

Uncertainty quantification and management in additive manufacturing: current status, needs, and opportunities (2017, methodology): “Table 1 Commonly available models in AM Model Methods Inputs Outputs Energy [23, 55–60] Connect energy consumption with total area of sintering (TAS) [23, 55, 59, 60], which is a function of slice thickness and building orientation ⋅ Laser power ⋅ Beam diameter ⋅ Scan speed ⋅ Absorptivity of powder ”
An overview of powder granulometry on feedstock and part performance in the selective laser melting process (2017, methodology): “Due to the complexity in monitoring powder bed activity, numerical models were developed and used to investigate laser-powder interactions and study the dynamic changes of the process [14,98].”
The present and future of additive manufacturing in the aerospace sector: A review of important aspects (2015, methodology): “Gürtler et al.(72) used the three-dimensional (3D) volume of fluid method to study the effect of the powder-layer thickness, power, scan spacing and scan velocity on the process dynamics.”
Microstructure modelling for metallic additive manufacturing: a review (2020, methodology): “In order to simulate the fluid flow within the melt, the mass and momentum equation have to be included alongside the energy equation (Gürtler et al. 2013; Yuan and Gu 2015): d dt (rH)+∇ · (r vH)−∇ · (k∇T ) = QS, (2) dr dt +∇ · (r v) = Ms, (3) r d v dt + r v · ∇ v = −∇p+ mD v +Ms v + F.…”
Additive manufacturing for energy: A review (2020, methodology): “tions of each phase, along with a scalar equation of the liquid volume fraction (F) [163,171]:”