Fluid and particle dynamics in laser powder bed fusion

By Prveen Bidare, I. Bitharas, R. M. Ward, Moataz M. Attallah, A. Moore. 2018

491 citations recorded by the source corpus.

Abstract In this work, we employ a combination of high-speed imaging and schlieren imaging, as well as multiphysics modelling, to elucidate the effects of the interaction between the laser beam and the powder bed. The formation of denuded areas where the powder was removed during single line and island scans over several layers were imaged for the first time. The inclination of the laser plume was shifted from forwards to backwards by changing power and scan speed, resulting in different denudation regimes with implications to the heat, mass and momentum transfer of the process. As the build progressed, denudation became less severe than for a single powder layer, but the occurrence of sintered and fused powder agglomerates, which were affected by the plume, increased. Schlieren imaging enabled the visualisation of the Ar gas flow, which takes place in the atmosphere above the bed due to the plume, in addition to its interaction with affected particles. Numerical modelling was used to understand and quantify the observed flow behaviour, through the hydrodynamic treatment of the laser plume as a multi-component Ar-Fe plasma. These results promote the characterisation of fluid dynamic phenomena during the laser powder-bed fusion (LPBF) process, which constitutes a key factor in the prevention of defects in additively manufactured parts.

Subfields: Automotive Engineering, Mechanical Engineering, Mechanics of Materials

View Paper: https://www.semanticscholar.org/paper/e50db72d6216745bf043224dc935cb2a6545c940

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In Automotive Engineering

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Citations in the corpus

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges (2021, background): “Powder Bed Fusion (PBF) Direct Metal Laser Sintering (DMLS) 3D Systems, Renishaw, SLM Solutions, Concept Laser (GE Additive), EOS, DMG Mori, Precious As shown in Figure 3c, in these processes thermal energy such as electron and laser beams selectively melts and fuses areas of a powder bed [31].”
In-situ measurement and monitoring methods for metal powder bed fusion: an updated review (2021, unknown): “Bidare et al (2018a) combined high-speed video imaging with high-speed Schlieren video imaging, which allowed visualizing the gas flow and its interaction with the plume and ejected spatters (figure 15(f)).”