Abstract
Nickel-based superalloys are one of the most industrially important families of metallic alloys at present. Selective Laser Melting (SLM), as one of the additive manufacturing technologies for directly forming complex metal parts, has been applied in the production of Inconel 718 components. Based on the more reasonable and comprehensive equivalent processing models (vaporization heat loss, equivalent physical parameters) for the nickel-based superalloy SLM process, an SLM molten pool dynamic behavior prediction model on the workpiece scale was established. Related equivalent processing models were customized by secondary development with the software Fluent. In order to verify the feasibility of the SLM molten pool dynamics model, the SLM single-pass employed to form the Inconel 718 alloy process was calculated. The simulated and experimental solidified track dimensions were in good agreement. Then, the influences of different process parameters (laser power, scanning speed) on the SLM formation of the Inconel 718 alloy were calculated and analyzed. The simulation and experimental solidified track widths were well-matched, and the result showed that, as a rule, the solidified track width increased linearly with the laser power and decreased linearly with the scanning speed. This paper will help lay the foundation for a subsequent numerical simulation study of the thermal-melt-stress evolution process of an SLM workpiece.
Highlights
Superalloys are suitable for long-term operation in high-temperature environments and meet corrosion and abrasion requirements
Panwisawas et al [22] carried out a numerical simulation of the dynamic behavior of the Selective Laser Melting (SLM) molten pool based on the open source computational fluid dynamics (CFD) code OpenFOAM, and compared the effects of different lamination thicknesses on the formation effects
According to the physical model solutiondescribed described above, dynamic behavior of the SLM molten pool on the workpiece scale was predicted by using Fluent
Summary
Superalloys are suitable for long-term operation in high-temperature environments and meet corrosion and abrasion requirements. Panwisawas et al [22] carried out a numerical simulation of the dynamic behavior of the SLM molten pool based on the open source computational fluid dynamics (CFD) code OpenFOAM, and compared the effects of different lamination thicknesses on the formation effects This kind of simulation method can directly describe the SLM formation process and directly predict the formation and evolution of defects, such as pores and balls, but the calculation requirements are often huge (the number of elements is tens of millions, and the required computing resources reach the order of 105 cpu.hrs). The so-called workpiece scale refers to the powder layer (including metal particles and pores) as a special material, indirectly describing the temperature and flow field evolution in the SLM forming process by setting equivalent physical parameters and flow behavior models, where the mesh size is often a few hundred microns, or even a few millimeters. This study can be expected to help lay the foundation for a subsequent numerical simulation study of the thermal-melt-stress evolution process of SLM parts
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