Abstract
A 3D Finite Element (FE) model was developed to investigate the thermal behaviour within the melt pool during point exposure to Selective Laser Melting (SLM) processed AlSi10Mg powder. The powder–solid transition, temperature-dependent thermal properties, melt pool convection, and recoating phase were taken into account. The effects of Exposure Time (ET) and Point Distance (PD) on SLM thermal behaviour were also investigated and showed that the short liquid phase time and high cooling rate of the melt pool reduced the viscosity of the melt pool at a lower ET or a higher PD. This resulted in poor wettability and the occurrence of balling and micropores. At a higher ET or lower PD the melt pool became unstable and allowed for easy formation of the self-balling phenomenon, as well as further partial remelting in the depth direction resulting in the creation of larger pores. The proper melt pool width (119.8 μm) and depth (48.65 μm) were obtained for a successful SLM process using an ET of 140 μs and a PD of 80 μm. The surface morphologies and microstructures were experimentally obtained using the corresponding processing conditions, and the results aligned with those predicted in the simulation.
Highlights
Al-Si alloys have excellent properties such as low density, specific strength, stiffness, and electrical and thermal conductivity
The results indicated that relatively higher scanning speeds produced a narrower melt pool width, causing large gaps and pores along the scanning direction
The abovementioned investigations into Selective Laser Melting (SLM)-processed Al alloy powder are all focused on thermal behaviours caused by parameters which are all in respect of the laser scan pattern of the continuous exposure scan
Summary
Al-Si alloys have excellent properties such as low density, specific strength, stiffness, and electrical and thermal conductivity. Established a Finite Element (FE) model and studied the temperature fields during the SLM process with AlSi10Mg powder under different laser powers and scanning speeds. Yu et al [4] established a 3D mesoscopic model using the Finite Volume Method so as to investigate the thermal behaviour of the melt pool during the SLM of AlSi10Mg powder under different laser powers and scanning speeds. The abovementioned investigations into SLM-processed Al alloy powder are all focused on thermal behaviours caused by parameters which are all in respect of the laser scan pattern of the continuous exposure scan. A 3D FE model was introduced to simulate the thermal behaviour and melt pool dimensions of AlSi10Mg alloy parts in the process of point exposure scan and to predict the relationship between processing parameters and microstructure defects. Corresponding experiments were carried out to study the microstructure of components produced by SLM, in order to verify the numerical results
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