Abstract
In the context of laser-based additive manufacturing, the thermal behavior of the substrate is relevant to define process parameters vis-à-vis piece quality. The existing literature focuses on two process variables: (a) lumped laser power and (b) process speed. However, this literature does not consider other variables, such as those related to the laser power distribution. To fill this vacuum, this manuscript includes the laser power spatial distributions (Gaussian, uniform circular and uniform rectangular) in addition to (a) and (b) above in 2D linear substrate heating simulations. The laser energy is modeled as a time dependent heat flux boundary condition on top of the domain. The total laser delivered power was identical for all spatial distributions. The results show that the laser intensity spatial distribution strongly affects the maximum temperature, and the depth and width of the heat affected zone. These 2D finite element simulations prove to be good options for digital twin based design environments, due to their simplicity and reasonable temperature error, compared to non-linear analysis (considered as ground truth for this case). Future publications address non-linear finite element simulations of the laser heating process (including convection and radiation and temperature dependent substrate properties).
Highlights
Metal Additive Manufacturing (AM) has enabled the fabrication of complex geometries that could not be build using traditional manufacturing techniques [1]
The spatial distribution of the laser power follows a Gaussian profile. This manuscript addresses the role of the laser power spatial distribution on the temperature field at the metal substrate
Our linear 2D initiative is obviously less precise than the 2D non-linear counterparts. We contend that it has value for approximate simplified purposes, e.g. digital twin applications, which require a reasonable appraisal of the substrate temperatures, at early design-stages
Summary
Metal Additive Manufacturing (AM) has enabled the fabrication of complex geometries that could not be build using traditional manufacturing techniques [1]. The characterization of the laser-based AM is still a matter of research. In this manuscript, we present an analysis of the influence of the laser intensity distribution, laser radius and process speed on the thermal behavior of the substrate. The analysis is carried out via numerical simulations of a 2D thermal model using the finite element method. The energy contributions of the laser into the substrate are modeled as time dependent heat flux (or Neumann) boundary conditions. We study the effects of three types of laser intensity distributions: Gaussian, uniform circular and
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