Mathematical Model for Metal Transfer Study in Additive Manufacturing with Electron Beam Oscillation

Alexey Shcherbakov,Alexander Gudenko,Alexey Goncharov,Andrey Sliva,Daria Gaponova,Viktor Dragunov,Regina Rodyakina

doi:10.3390/cryst11121441

Abstract

A computer model has been developed to investigate the processes of heat and mass transfer under the influence of concentrated energy sources on materials with specified thermophysical characteristics, including temperature-dependent ones. The model is based on the application of the volume of fluid (VOF) method and finite-difference approximation of the Navier–Stokes differential equations formulated for a viscous incompressible medium. The “predictor-corrector” method has been used for the coordinated determination of the pressure field which corresponds to the continuity condition and the velocity field. The modeling technique of the free liquid surface and boundary conditions has been described. The method of calculating surface tension forces and vapor recoil pressure has been presented. The algorithm structure is given, the individual modules of which are currently implemented in the Microsoft Visual Studio environment. The model can be applied for studying the metal transfer during the deposition processes, including the processes with electron beam spatial oscillation. The model was validated by comparing the results of computational experiments and images obtained by a high-speed camera.

Highlights

The process of metal transfer under the influence of concentrated heating sources is one of the most difficult objects to study
Main interest in the study of general patterns of metal transfer has increased recently. It can be associated with the advent of technologies for additive manufacturing of products made of metal materials supplied both in powder form [3,4,5,6] and in wire form [7,8]
Mathematical modeling methods are rather relevant due to the fact that they can be used to obtain the data on processes that have occurred in a molten pool by conducting computational experiments

Summary

Introduction

The process of metal transfer under the influence of concentrated heating sources is one of the most difficult objects to study. Experimental research methods do not allow obtaining information on the distribution of flow velocities, temperature, and pressure in the volume of a molten pool.

Results

Conclusion