Abstract
This work presents a computationally efficient predictive model based on solid heat transfer for temperature profiles in powder bed metal additive manufacturing (PBMAM) considering the heat transfer boundary condition and powder material properties. A point moving heat source model is used for the three-dimensional temperature prediction in an absolute coordinate. The heat loss from convection and radiation is calculated using a heat sink solution with a mathematically discretized boundary considering non-uniform temperatures and heat loss at the boundary. Powder material properties are calculated considering powder size statistical distribution and powder packing. The spatially uniform and temperature-independent material properties are employed in the temperature prediction. The presented model was tested in PBMAM of AlSi10Mg under different process conditions. The calculations of material properties are needed for AlSi10Mg because of the significant difference in thermal conductivity between powder form and solid bulk form. Close agreement is observed upon experimental validation on the molten pool dimensions.
Highlights
Powder bed metal additive manufacturing (PBMAM), referred to as powder bed fusion (PBF), can produce geometrically complex parts in a single unit or small batch with effective cost [1].High-density laser power is employed in PBMAM to fully melt and fuse metal powders to build parts in a layer-by-layer manner [2]
The presented model was employed for the temperature prediction in multiple single-track scans during PBMAM of AlSi10Mg under different process conditions
The material properties of the powder bed were used in the temperature prediction, in which the powder material properties of the powder bed were used in the temperature prediction, in which the powder material properties were calculated with consideration of the powder size distribution and powder packing properties were calculated with consideration of the powder size distribution and powder packing under the air atmosphere
Summary
Powder bed metal additive manufacturing (PBMAM), referred to as powder bed fusion (PBF), can produce geometrically complex parts in a single unit or small batch with effective cost [1]. To overcome the limitations in experimental techniques, finite element analysis (FEA)-based numerical models and physics-based analytical models were developed for the temperature prediction. Analytical models were for temperature prediction in PBMAM without resorting to the FEA or iteration-based simulations, which significantly reduced the expensive computational cost. Semi-analytical models were developed to consider heat transfer boundary conditions. Yang et al proposed another semi-analytical model for temperature prediction in SLM, in which the temperature change due to the heat input from moving laser and the heat loss at boundary were calculated by an analytical and numerical model, respectively [29]. This work presents a physics-based analytical model to predict the three-dimensional temperature distribution in the single-track scans of PBMAM of AlSi10Mg considering the heat transfer boundary conditions and powder bed material properties.
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