Abstract
Additive Manufacturing is in progress to change the production and manufacturing environments and possibilities; however, the complex processes taking place are not completely understood yet. A better understanding of the incorporation mechanism of the particles into the melt pool during blown powder processes could lead to methods to increase the powder and energy efficiency. Therefore, the incorporation mechanism was investigated in experiments and simulation. High-speed images made it possible to observe the behavior of single particles on the melt pool. A model based on the temperature-dependent surface tension/energy difference between the particle and the melt pool calculated the time until particle incorporation. It was shown that the surface tension characteristics during particle heating can even lift the particle from the melt pool. The calculated wetting behavior in combination with high kinetic energies should lead to an immediate immersion of the particle into the melt pool. Since observations do not show this behavior, it is concluded that the surface tension plays a role in the incorporation mechanism, but other effects like the occurrence of oxide layers or additional particle heating by the laser beam seem to lead to different mechanisms and heat conductions to support an earlier incorporation.
Highlights
Building structures from wire or powder material for creating [1] or repairing [2] industrial parts are the main driving forces and applications of Additive Manufacturing in production
Reasons might be the additional heating of the particles by the laser beam in the experiments, which was not considered in the model or the chosen stop condition, which defines the incorporation time
It can be assumed that the surface tension effect is one of the driving forces for the floating effect of the particle on the liquid melt pool
Summary
Building structures from wire or powder material for creating [1] or repairing [2] industrial parts are the main driving forces and applications of Additive Manufacturing in production. The use of wire or powder material makes it possible to create the desired geometries without wasting much material compared to subtractive machining. Thereby, the production of parts from expensive base materials or bigger structures becomes more attractive. Complex geometries can be realized [3], like overhangs to build, e.g., light-weight designs [4]. Additive Manufacturing processes are based on the accumulation of applied material and usually melting to form the desired geometry of a new part. The additional material is usually applied as wire or powder
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