Abstract
A three dimensional finite element model (FEM) was established to simulate the temperature distribution, flow activity, and deformation of the melt pool of selective laser melting (SLM) AZ91D magnesium alloy powder. The latent heat in phase transition, Marangoni effect, and the movement of laser beam power with a Gaussian energy distribution were taken into account. The influence of the applied linear laser power on temperature distribution, flow field, and the melt-pool dimensions and shape, as well as resultant densification activity, was investigated and is discussed in this paper. Large temperature gradients and high cooling rates were observed during the process. A violent flow occurred in the melt pool, and the divergent flow makes the melt pool wider and longer but shallower. With the increase of laser power, the melt pool’s size increases, but the shape becomes longer and narrower. The width of the melt pool in single-scan experiment is acquired, which is in good agreement with the results predicted by the simulation (with error of 1.49%). This FE model provides an intuitive understanding of the complex physical phenomena that occur during SLM process of AZ91D magnesium alloy. It can help to select the optimal parameters to improve the quality of final parts and reduce the cost of experimental research.
Highlights
There is a growing interest in the use of magnesium alloys in automotive and aerospace industries, a reason behind which is their very low density compared to aluminum alloys (2/3 of density at room temperature) and steel (2/9 of density at room temperature) [1]
Surface stress caused by the Marangoni effect and gravity in flow generation, the phase change latent heat, and Gaussian distributed laser beam were considered in building the model
The color map represents the temperature field, and the black line is the melt point isotherm of the AZ91D alloy which shows the boundary of the melt pool representatively
Summary
There is a growing interest in the use of magnesium alloys in automotive and aerospace industries, a reason behind which is their very low density compared to aluminum alloys (2/3 of density at room temperature) and steel (2/9 of density at room temperature) [1]. The low density gives them high specific strength and modulus, coupled with their excellent thermal and damping characteristics, making them a potential candidate for low-temperature structural applications in the aerospace and automotive industries [2,3,4] They have defects such as low creep resistance and easy corrosion, which limit their application in industrial and medical fields. Magnesium AZ91A, B, C, D, and E have the same nominal compositions but differ in ranges and/or specified impurity limits This high-purity alloy has excellent corrosion resistance. Casting is prone to defects such as porosity, which reduces the mechanical properties of is prone to defects such as porosity, which reduces the mechanical properties of the manufactured the manufactured part [7] This drives the research of new manufacture methods for magnesium part [7].
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