Ray tracing heat source model for polymer powder bed fusion considering laser energy absorption and multiple reflection

Abstract

Powder bed fusion is considered one of the most promising additive manufacturing technologies, but the generation and evolution of volumetric heat source involved in the powder bed fusion process remain unclear as laser-powder bed interactions has not been fully developed. In this work, a ray tracing model is established to simulate the laser-powder bed interaction during the powder bed fusion process. Five types of powder beds with homogeneous and non-homogeneous particle radius distributions are generated using the discrete element method, and then the energy distributions in the ray tracing heat source are explored by considering laser energy absorption and multiple reflection. The results indicate that the energy distribution in the ray tracing heat source basically exhibits a Gaussian-like trend in the horizontal plane and an exponential decay in the vertical direction. The fitting coefficients Z0 (related to laser power) and η2 (related to laser radius) of the ray tracing heat source for different powder beds show maximum differences of 21.87 % and 72.22 %, respectively, compared to conventional Gaussian volumetric heat sources. The deviation between the fitting coefficient η3 (related to laser energy attenuation) and the corresponding fitted attenuation coefficient of the powder bed is related to the overall uniformity of the powder bed. Due to multiple reflections of the laser within the powder bed, the ray tracing heat source has larger width and depth as compared to Gaussian volumetric heat source. This study is significant because it provides a more accurate heat source model for the reliable prediction and safe operation of powder bed fusion process.