Abstract
Investigation of the selective laser melting (SLM) process, using finite element method, to understand the influences of laser power and scanning speed on the heat flow and melt-pool dimensions is a challenging task. Most of the existing studies are focused on the study of thin layer thickness and comparative study of same materials under different manufacturing conditions. The present work is focused on comparative analysis of thermal cycles and complex melt-pool behavior of a high layer thickness multi-layer laser additive manufacturing (LAM) of pure Titanium (Ti) and Inconel 718. A transient 3D finite-element model is developed to perform a quantitative comparative study on two materials to examine the temperature distribution and disparities in melt-pool behaviours under similar processing conditions. It is observed that the layers are properly melted and sintered for the considered process parameters. The temperature and melt-pool increases as laser power move in the same layer and when new layers are added. The same is observed when the laser power increases, and opposite is observed for increasing scanning speed while keeping other parameters constant. It is also found that Inconel 718 alloy has a higher maximum temperature than Ti material for the same process parameter and hence higher melt-pool dimensions.
Highlights
Additive manufacturing (AM) has sustained and advanced as a manufacturing process from rapid prototyping (RP)
Given the importance of laser additive manufacturing (LAM) in aerospace and biomedical applications combined with the ever-expanding use of Ti material and Inconel 718 alloy, these two materials are considered in the present study
The present paper shows the comparative numerical investigation of laser-based additive manufacturing of high layer thickness materials
Summary
Additive manufacturing (AM) has sustained and advanced as a manufacturing process from rapid prototyping (RP). Given the importance of LAM in aerospace and biomedical applications combined with the ever-expanding use of Ti material and Inconel 718 alloy, these two materials are considered in the present study Another major hindrance is the high manufacturing lead time, which is largely because of the very thin layer thickness. The present study is focused on the investigation of thermal interaction and change in melt-pool dimensions due to thermal interactions in between the layers and substrates in a high layer thickness multi-layer LAM process of pure Ti and Inconel 718 materials and comparatively analyze the results. Where q, η, P and r represents the rate of laser heat flux, the efficiency of the laser beam absorption, absolute laser beam power, effective radius of the laser beam at the surface of the layer. x and y depict the position of the centre of the laser beam at a specific time and at the respective layer
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