A three-dimensional mesoscopic model, considering the powder-to-solid transition, motion of gas bubbles within molten pool and the effect of surface tension, has been established in order to investigate the evolution rule of pores and re-melting densification mechanism during selective laser melting of AlSi10Mg. The results indicated that re-melting phenomenon of previous fabricated layer induced by laser melting of current powder layer played a crucial role on the increase in densification rate. During the re-melting process, the trapped gas pores in previous layer rose up swiftly and came to the surface consequently, resulting in remarkably elevated densification in previous layer. The influences of laser scan speed on the single-track morphology, types of pores and laser penetration depth have also been studied. It showed that the maximum re-melting depth (31 µm) was attained, and meanwhile, pores left in preceding layer got eliminated completely due to the mass transfer within molten pool, when an appropriate laser scan speed (150 mm/s) was applied. In this case, reasonable laser energy per unit length and irradiation time tended to enhance the laser penetration depth for powder bed and decrease the porosity in as-fabricated layer. A series of experimental study were performed to verify the reliability of the above mesoscopic simulation, including the surface topography of single track and the types of pores. The redistribution of bubbles between the adjacent layers as well as the localized re-melting densification, which were observed from the longitudinal section of samples, was in good agreement with simulation results.
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