Pool Characteristics Research Articles

Evolutionary Mechanism of Solidification Behavior in the Melt Pool during Disk Laser Cladding with 316L Alloy

Laser cladding is an emerging environmentally friendly surface-strengthening technology. During the cladding process, the changes in molten pool temperature and velocity directly affect the solidification process and element distribution. The quantitative revelation of the directional solidification mechanism in the molten pool during the cladding process is crucial for enhancing the quality of the cladding layer. In this study, a multi-field coupling numerical model was developed to simulate the coating process of 316L powder on 45 steel matrices using a disk laser. The instantaneous evolution law of the temperature and flow fields was derived, providing input conditions for simulating microstructure evolution in the molten pool’s paste zone. The behavior characteristics of the molten pool were predicted through numerical simulation, and the microstructure evolution was simulated using the phase field method. The phase field model reveals that dendrite formation in the molten pool follows a sequence of plane crystal growth, cell crystal growth, and columnar crystal growth. The dendrites can undergo splitting to form algal structures under conditions of higher cooling rates and lower temperature gradients. The scanning speed of laser cladding (6 mm/s) has minimal impact on dendrite growth; instead, convection within the molten pool primarily influences dendrite growth and tilt and solute distribution.

Welding Defect Monitoring Based on Multi-Scale Feature Fusion of Molten Pool Videos.

Real-time quality monitoring through molten pool images is a critical focus in researching high-quality, intelligent automated welding. However, challenges such as the dynamic nature of the molten pool, changes in camera perspective, and variations in pool shape make defect detection using single-frame images difficult. We propose a multi-scale fusion method for defect monitoring based on molten pool videos to address these issues. This method analyzes the temporal changes in light spots on the molten pool surface, transferring features between frames to capture dynamic behavior. Our approach employs multi-scale feature fusion using row and column convolutions along with a gated fusion module to accommodate variations in pool size and position, enabling the detection of light spot changes of different sizes and directions from coarse to fine. Additionally, incorporating mixed attention with row and column features enables the model to capture the characteristics of the molten pool more efficiently. Our method achieves an accuracy of 97.416% on a molten pool video dataset, with a processing time of 16 ms per sample. Experimental results on the UCF101-24 and JHMDB datasets also demonstrate the method's generalization capability.

Are pools created when restoring extracted peatlands biogeochemically similar to natural peatland pools?

In the last 25 years, several degraded peatlands in eastern Canada have been restored toward their natural structure. Pools are common in natural peatlands and are important habitats for unique flora and fauna. Because of their ecological value, pools have been created in some restored peatland sites. Nevertheless, the biogeochemistry of created pools in a restoration context has seldom been studied. The objective of our study is to characterize the biogeochemistry of created pools from restored peatlands and compare them with natural pools along a chronosequence since their creation. We measured different biogeochemical variables (pH, concentrations of nitrogen (N), phosphorus (P), dissolved organic carbon (DOC), dissolved organic matter (DOM), base cations-calcium (Ca), sodium (Na), magnesium (Mg), and potassium (K)-and dissolved gases-methane (CH4), carbon dioxide (CO2), and nitrous oxide (N2O)-) in 61 pools distributed over seven peatlands in eastern Canada. The sites represent a range of conditions, from natural to restored peatlands with pools ranging from 3 to 22 years old. Created and natural pools had distinctive biogeochemistry, with created pools being generally less acidic (pH >5) and 2.5 times more concentrated in nutrients (N and P) than in natural pools. DOC, N, P, dissolved gases, and base cations concentrations were lower in natural pools than in created pools, and varied between created sites. The oldest created pools (age >17 years) tend to approach the biogeochemical characteristics of natural pools, indicating that created pools may, over time, provide habitats with similar conditions to natural pools. A return of created pools to a natural pool-like biogeochemistry could thus inform on the success of peatland restoration.

Research on energy utilization of electron beam melting for silicon purification

As a key material for solar photovoltaic power generation, the purity of silicon plays a crucial role in the photovoltaic conversion efficiency and performance. The electron beam melting (EBM), which is irreplaceable metallurgical methods, has been widely used for silicon purification. However, high energy consumption result in relatively high cost, which limits its widespread application in melting industry. This study was centered on the energy distribution that proposes a new approach to reducing energy consumption during EBM. The scanning form of electron beam is most important factor concerning energy consumption. Different scanning forms can affect the characteristics of molten pool which is closely correlated with the purification process. In this study, efficient and energy-saving preparation processes of EBM are being explored through the numerical model and experimental. The relationship of energy distribution form and purification efficiency is studied. The research results indicate that electron beam scanning under uniform distribution can achieve more uniform temperature and flow field distribution in the molten pool, which has a higher energy utilization rate during silicon purification by EBM. The mathematical model established in this study can effectively predict the energy consumption level under different melting parameters, providing important reference for the optimization and energy conservation of EBM process for other materials. In addition, evaporation characteristics of volatile impurity, migration of the second phase particles in the melt, controlling of melt pool characteristics and the crystal growth control all can be conducted based on this study.

An image-based nonparametric multivariate EWMA control chart for metal additive manufacturing process monitoring

Additive manufacturing offers considerable promise in terms of manufacturing flexibility, but print quality remains a major obstacle to its widespread adoption. Consequently, timely and accurate detection of process variations or anomalies is critical for implementing corrective actions. Melt pool characteristics are crucial to final product quality, and current state-of-the-art studies on melt pool image flow have primarily focused on in-situ sensing, feature extraction, and their relationship with process settings and material properties. This study aims to develop a statistical process control approach to detect process variations immediately using a predefined distribution of monitoring statistics. Two main challenges are addressed: 1) the unknown distribution of melt pool image features, rendering traditional parametric control charts unreliable and 2) the autocorrelation of melt pool image flow features, violating the traditional control chart assumption of independent and identically distributed monitoring data. To overcome these challenges, we propose a multivariate nonparametric Exponential Weighted Moving Average (EWMA) control chart that can appropriately accommodate stationary serial data correlation to monitor process stability by tracking physical features extracted from the original images. Key features of the proposed control chart include its ability to eliminate serial correlation effects and its distribution-free nature, requiring no prior information about the data distribution. Comparative analysis of simulated and real data demonstrates that the proposed approach outperforms baseline methods in anomaly detection accuracy. An actual case study in laser metal deposition (LMD) further validates the effectiveness of the proposed method.

Laser powder bed fusion of Mg–Zn–Zr alloy: Formability, microstructure evolution and biodegradation behavior

Laser powder bed fusion (LPBF) was used to fabricate Mg–Zn–Zr (ZK60) parts, with a thorough investigation of processability by varying laser power and scanning rate. The combined effect of these parameters, which determines laser energy density, significantly impacted the forming quality of LPBF ZK60. Dense parts (over 99%) free of visible defects such as pores and cracks were achieved at a laser energy density of 74.1 J/mm2. The formation mechanisms of pores and cracks were extensively analyzed concerning the characteristics of the molten pool and subsequent cooling behavior. The LPBF ZK60 parts exhibited extremely fine grains, with an average grain size of 3.2 μm. Both equiaxed and columnar grains were observed, with a central equiaxed zone in the melt pool and a perpendicular lamellar zone along its boundary. Additionally, the Mg7Zn3 eutectic phase precipitated within the α-Mg matrix of ZK60. Immersion and electrochemical tests indicated that the XZ plane displayed superior corrosion resistance, attributed to fewer deformation regions and lower dislocation density. Furthermore, in vitro cell experiments confirmed that the ZK60 alloy possesses good biocompatibility.

A Robust Recurrent Neural Networks-Based Surrogate Model for Thermal History and Melt Pool Characteristics in Directed Energy Deposition.

In directed energy deposition (DED), accurately controlling and predicting melt pool characteristics is essential for ensuring desired material qualities and geometric accuracies. This paper introduces a robust surrogate model based on recurrent neural network (RNN) architectures-Long Short-Term Memory (LSTM), Bidirectional LSTM (Bi-LSTM), and Gated Recurrent Unit (GRU). Leveraging a time series dataset from multi-physics simulations and a three-factor, three-level experimental design, the model accurately predicts melt pool peak temperatures, lengths, widths, and depths under varying conditions. RNN algorithms, particularly Bi-LSTM, demonstrate high predictive accuracy, with an R-square of 0.983 for melt pool peak temperatures. For melt pool geometry, the GRU-based model excels, achieving R-square values above 0.88 and reducing computation time by at least 29%, showcasing its accuracy and efficiency. The RNN-based surrogate model built in this research enhances understanding of melt pool dynamics and supports precise DED system setups.

Surface roughness and pore evolutions in multi-layer laser powder bed fusion of extra-low interstitial Ti-5Al-2.5Sn powder: A numerical study

In this paper, the three-dimensional discrete element method (DEM) and computational fluid dynamics (CFD) coupled approach was used to numerically reproduce the whole process of laser powder-bed-fusion (L-PBF) additive manufacturing (AM) of extra-low interstitial (ELI) Ti-5Al-2.5Sn powder. The effects of key parameters such as scanning strategy and hatch spacing (h) on the surface roughness (Ra) and pores during multi-layer printing are systematically investigated by characterizing the molten pool characteristics and thermal behavior upon laser motion; and the melt volume in this duration is quantified by the volume of fluid (VOF) method to demonstrate inter-layer interactions. The results show that Ra can be categorized according to the scanning directions. Along the scanning direction, the Ra is affected by the heat accumulation effect and increases as the h decreases. In this case, the Ra caused by the Marangoni effect can be reduced by increasing the melt volume at the end of the track through the layer rotation. The Ra perpendicular to the scanning direction is caused by the ripple-like surface formed by track overlap and decreases as the h decreases. For defects, the pores formed by shrinkage due to insufficient melting or by lack of fusion (LoF) due to incomplete track overlap decrease with the decrease of h. The LoF pores caused by weak inter-layer metallurgical bonding are affected by the surface morphology of the previous layer, which is increased as the h increases. The layer rotation can also reduce such LoF pores. On this basis, a quality control chart suitable for actual production is established.

Microstructural evolution and mechanical properties of maraging steel by additive manufacturing

Laser powder bed fusion (LPBF) is a revolutionary and innovative technology that provides advanced technical support for the forming of parts with high precision and complex structures. In this work, a new type of Fe-Ni-Mo-Ti-Al-Y cobalt-free maraging steel was successfully fabricated by LPBF. The additive manufacturing parameters and the microstructural evolution of cobalt-free maraging steel under different heat treatment parameters were systematically studied. The results show that the parts without cracks and close to complete density can be fabricated under a wide LPBF process window. The dislocation cell with 500 nm in the printing state makes the material have good plasticity. After post-heat treatment, the preferred orientation of LPBF maraging steel is reduced, but the typical characteristics of molten pool and cellular structure in maraging steel disappeared, which is the result of local composition and microstructure homogenization. The elongation of LPBF maraging steel in solution annealed state is higher than that in as-printed state, which is due to the reduction of dislocation density and grain coarsening. However, after direct aging, due to the formation of nano-sized Ni3(Ti, Mo) precipitates in the matrix, the mechanical properties of the material were effectively enhanced, and the tensile strength increases from ∼1.1 GPa in as-printed state to ∼1.6 GPa in aging state. In contrast, the corrosion resistance of as-printed maraging steel is higher and comparable to that of traditional cobalt-containing maraging steel. However, the corrosion resistance of LPBF maraging steel after being aged is reduced, which is due to the existence of precipitates and dislocations. This study provides a theoretical reference for the composition design and strengthening mechanism of LPBF cobalt-free maraging steel.

Study on asymmetric forming and performance strengthening mechanisms of 6061-T6 aluminum alloy joints fabricated by oscillating laser based on keyhole characteristics and molten pool dynamic behaviors

The study intends to unravel the processes behind the particular forming and performance improvement of 6061-T6 aluminum alloy joints by getting a thorough understanding of keyhole features and dynamical characteristics of molten pools during the laser welding with circular oscillation (C-OLW) process. The C-OLW experiments were carried out considering the pivotal parameters, including oscillation frequency (f) and amplitude (A), and their impacts on joint formation, microstructure, and performance were analyzed. Increasing f from 200 Hz to 300 Hz results in a more homogeneous and centered laser energy distribution, reducing weld breadth and the maximum depth. Raising A from 1.2 mm to 1.5 mm concentrated energy along the workpiece surface, increasing weld breadth but decreasing the maximum weld depth. A three-dimensional transient numerical model was established and verified. The simulation results reveal that increasing f considerably improves keyhole stability by virtue of the beam's mixing effect on energy, resulting in a more evenly distributed temperature within the molten pool. The velocity of the beam's motion intensifies, leading to elevated local temperature and subsequently causing an escalation in splattering. When A grows, keyhole stability reduces, as does the intensity of molten pool flow. The major effect of increased frequency is refining the grain size while increasing amplitude primarily promotes the columnar-to-equiaxed transition (CET) process. The extracted results of temperature distribution illustrate that an increase in f leads to an increase in the solidification rate (R), and temperature gradient values (G) are similar or higher along the same isotherm. Therefore, the G/R ratio rises, promoting the formation of finer microstructures. Although increasing A diminishes G, the reduced overall temperature and molten pool volume contribute to the rise in R. Consequently, the G/R ratio declines, fostering equiaxed grain growth, in line with experimental observations. A higher G value on the left side corresponds to finer grain structures, corroborating experimental findings via Electron Backscatter Diffraction (EBSD). The keyhole stability and microstructure characteristics explain why increasing f or A can enhance joint performance. The research reveals that strategically augmenting both oscillation frequency and amplitude enables the achievement of enhanced performance in 6061-T6 aluminum alloy joints.

A study integrating in-process thermal signatures, microstructure, and corrosion behaviour of AISI 316L coatings on low carbon steel substrate deposited by laser-directed energy deposition (L-DED)

Surface coating through Laser Directed Energy Deposition (L-DED) of AISI 316L on low-carbon steel was carried out by varying laser fluence. The resulting melt pool characteristics, obtained through IR pyrometer, played a significant role in evolution of the microstructure. A higher heat input resulted in an equiaxed grain structure with finer grain sizes and improved deposition quality. The quantitative phase analysis revealed the presence of a dominant austenite phase and a secondary ferrite phase, along with traces of molybdenum carbide. Corrosion analysis reveals improved resistance at a higher laser fluence, attributed to increased content of corrosion-resistant alloying elements (Mo, Cr) and predominance of the austenite phase. Electrochemical Impedance Spectroscopy (EIS) confirms a higher corrosion resistance at a higher laser fluence, supported by a significantly higher polarization resistance and presence of a duplex-structured passive film. Results indicate that moderate laser fluence levels, ranging from 5 to 7.5 kJ/cm2, accompanied by medium to high thermal signatures and moderate cooling rates, yield coatings with refined microstructures, enhanced mechanical strength, and corrosion resistance. For superior corrosion resistance, a laser fluence of 10 kJ/cm2 is recommended, although careful consideration of its potential impact on mechanical properties is advised.

Characteristics of the Soil Organic Carbon Pool in Paddy Fields in Guangdong Province, South China

To understand the role of paddy soils in the global carbon cycle, it is necessary to analyze the characteristics of the organic carbon pool at different soil depths. It was hypothesized that soil organic carbon fractions including labile organic carbon fraction I (LOCF-I), labile organic carbon fraction II (LOCF-II), and recalcitrant organic carbon (ROC) distributed differently within the soil profile. In this study, soil was collected from 27 typical rice fields in Guangdong Province, south China. The carbon fractions of the paddy field soils were analyzed and compared over a 0–60 cm depth profile. The relationship between carbon content and the physical and chemical properties of the soils was further analyzed using correlation analysis and structural equation modeling. The results showed that soil total organic carbon concentration in paddy fields was increased by 22.1% during the last four decades. In the soil organic carbon pool of 0–60 cm profile, the proportion of 67.31 to 70.31% in ROC, 21.75 to 22.06% in LOCF-I, and 7.7 to 10.63% was recorded, respectively, indicating that ROC was the dominating fraction. Storage of soil total organic carbon and fractions all decreased with the increase in soil depth. Correlation and path analysis showed that total nitrogen was the main driving factor affecting the soil carbon fractions, whereas pH and soil bulk density indirectly affected the content of carbon fractions by influencing total nitrogen. The results imply the importance of soil total nitrogen in paddy carbon management of rice cultivation.

Computational Modeling and Experimental Validation of Thermal Stress and Melt Pool Characteristics Using High Power Laser Diode Beam on 7075 Aluminum Alloy

Computational Modeling and Experimental Validation of Thermal Stress and Melt Pool Characteristics Using High Power Laser Diode Beam on 7075 Aluminum Alloy

Experimental study on heat transfer characteristics of R245fa pool boiling outside horizontal tubes

Full-liquid evaporator is an important part of the Organic Rankine Cycle (ORC). It is of great guiding significance to study the pool boiling heat transfer characteristics (high-temperature level) of the evaporator heat exchange tube for evaporator design. The pool boiling heat transfer characteristics (high-temperature level) of working fluid R245fa outside smooth tube and fish-scale tube are analyzed. The outcomes exhibit that the overall Heat Transfer Coefficient (HTC) of the smooth tube is 1.9–3.9 kW m−2 K−1, and the fish-scale tube is 3.8–4.3 kW m−2 K−1 when the saturation temperature of organic working medium R245fa is 80.5 °C. The HTC outside the fish scale tube is 1.45–3.13 instances that of the smooth tube. The external HTC of the smooth tube and fish-scale tube increases with the increase of heat flux, but the strengthening rate decreases. After the outer wall of the heat exchange tube used in the ORC evaporator is strengthened, the water velocity in the tube increases, which can not only strengthen the heat exchange in the tube but also play an anti-scaling effect.

Sensitivity of Coastal Squall-Line Evolution to Numerical Sea-Breeze Initialization Method

Abstract This study employs 3D idealized numerical experiments to investigate the physical processes associated with coastal convection initiation (CI) as an offshore-moving squall line traverses a mountainous coastal region. A squall line can propagate discretely as convection initiates over the lee slope downstream of the primary storm as the cold pool collides with a sea breeze. Intensity of the initiating convection, thus the downstream squall line, is sensitive to the sea-breeze numerical initialization method, since it influences sea-breeze and cold pool characteristics, instability and vertical wind shear in the sea-breeze environment, and ultimately the vertical acceleration of air parcels during CI. Here, sea breezes are generated through four commonly used numerical methods: a cold-block marine atmospheric boundary layer (MABL), a prescribed surface sensible heat flux function, a prescribed surface sensible plus latent heat flux functions, and radiation plus surface-layer parameterization schemes. For MABL-initialized sea breezes, shallow weak sea-breeze flow in a relatively low instability environment results in weak CI. For the remainder, deeper stronger sea-breeze flow in an environment of enhanced instability supports more robust CI. In a subset of experiments, however, the vertical trajectory of air parcels is suppressed leading to weaker convection. Downward acceleration forms due to the horizontal rotation of the sea-breeze flow. Accurate simulations of coastal convective storms rely on an accurate representation of sea breezes. For idealized experiments such as the present simulations, a combination of initialization methods likely produces a more realistic representation of sea breeze and the associated physical processes.

Unraveling the interrelation between process parameters and defects to enhance the strength of laser additively manufactured CuZrAlTi bulk metallic glass

Laser powder bed fusion (LPBF) enables the production of large and intricately shaped bulk metallic glasses (BMGs); however, the current strength of LPBF-fabricated BMGs is significantly lower than their cast counterparts due to defects generated during the LPBF process in the as-built BMGs. In this study, considering the viscosity characteristics of BMG melts and their impact on melt pool characteristics, we investigated the relationship between LPBF parameters, structural characteristics, and defects in a selected Cu45Zr45Al6Ti4 BMG. Our findings revealed a transition of the melt pool from conduction mode to keyhole mode and subsequently to extended mode with increasing laser power. Furthermore, we explored how melt pool characteristics influence defects such as pores, heat affected zone (HAZ), and crystalline phase in the as-built Cu45Zr45Al6Ti4 BMG. Under optimized LPBF parameters, we successfully fabricated nearly fully amorphous Cu45Zr45Al6Ti4 BMG samples with high density (>99%) and absence of cracks. The printed samples exhibited a compressive strength of 1839 MPa comparable to their cast counterparts while achieving an impressive tensile strength value of 920 MPa, currently the highest reported for CuZr-based BMGs. This study enhances our understanding of the intrinsic relationship between LPBF parameters, melt pool characteristics, defects, and mechanical properties of LPBF-fabricated BMGs while providing a new parameter optimization strategy for reducing defects and achieving high strength in BMGs.

Melt Pool characteristics on surface roughness and printability of 316L stainless steel in laser powder bed fusion

Purpose Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel. Design/methodology/approach A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy. Findings The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm3) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation. Originality/value This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.

Potential kidney donors among patients with out-of-hospital cardiac arrest and a termination of resuscitation rule

ImportanceUncontrolled donation after circulatory determination of death (uDCD) has been developed and can serve as a source of kidneys for transplantation, especially when considering patients that meet extended criteria donation (ECD). ObjectiveThis study assessed the theorical size and characteristics of the potential pool of kidney transplants from uDCD with standard criteria donation (SCD) and ECD among patients who meet Termination of Resuscitation (TOR) criteria following Out of Hospital Cardiac Arrest (OHCA). Methods and participantsThis study focused on adult patients experiencing unexpected OHCA, who were prospectively enrolled in the Parisian registry from May 16th, 2011, to December 31st, 2020. ResultsDuring the study period, EMS attempted resuscitation for 19,976 OHCA patients, of which 64.5% (12,890) had no return of spontaneous circulation. Among them, 47.4% (9,461) had TOR criteria, representing no chance of survival, and from them, 8.8% (1,764) met SCD criteria and could be potential organ donors and 33.6% (6,720) met ECD for kidney donors. The mean potential number per year of uDCD candidates with SCD and ECD remain stable respectively around 98 (±10.8) and 672 (±103.8) cases per year. Elderly patients (≥65 y.o.) represented 61.2% (n = 5,763/9,461) of patients who met TOR and 100% (5763/5763) of patients who could have matched both ECD criteria and TOR. Conclusion and relevanceImplementing uDCD program including SCD and ECD for kidney transplantation among OHCA cases quickly identified by the TOR, holds significant potential to substantially broaden the pool of organ donors. These programs could offer a viable solution to address the pressing burden of kidney shortage, particularly benefiting elderly recipients who may otherwise face prolonged waiting times and limited access to suitable organs.

Effects of Straw and Biochar Amendments on Characteristics of Soil Fungal Community and Organic Carbon Pool in Jasminum sambac Garden

In order to elucidate the changes in the soil fungal community and soil organic carbon components of a Jasminum sambac garden after straw and biochar application, we measured the organic carbon components and soil fungal community of the 0-15 cm soil layer in a J. sambac garden, which was divided into a control group, straw treatment group, and biochar treatment group. The carbon pool management index （CPMI） was also calculated. The results showed that the diversity of the soil fungal community was decreased after straw and biochar application, and the structure of dominant fungal genera was changed in each treatment. The soil fungal community structure in the biochar treatment was significantly different from that in the straw treatment and control groups. Redundancy analysis （RDA） showed that soil fungal community structure was mainly affected by soil bulk density, C∶N, salinity, and TN. Secondly, compared with that in the control group, soil labile organic carbon （LOC） in the straw treatment group was significantly increased by 87.44% （P<0.05）, whereas soil dissolved organic carbon （DOC） and microbial biomass carbon （MBC） in the biochar treatment group were significantly increased by 22.27% and 23.17% （P<0.05）, respectively. Further, compared with that in the control group, the carbon pool activity （L） under straw treatment was significantly increased （P<0.05）, and the carbon pool index （CPI） under biochar treatment was significantly increased （P<0.05）. Spearman correlation analysis showed that the distribution characteristics of soil organic carbon active components were regulated by the dominant fungi. FUNGuild functional prediction results showed that saprophytic and its facultative nutritional fungi had an important impact on soil organic carbon active components and carbon pool management index after straw and biochar application.

Avoiding heat source calibration for finite element modeling of the laser powder bed fusion process

The melt pool characteristics govern process stability and microstructure development during Laser Powder Bed Fusion (LBPF). The melt pool is strongly affected by the laser parameters and based on the melt pool depth-to-width ratio, three melting modes can be distinguished: conduction, transition, and keyhole mode. Finite element (FE) simulations have been extensively used to investigate the cyclic thermal history of the LPBF process and the effects of different process parameters on the part quality. However, the heat sources applied in such simulations can only accurately predict the melt pool behavior, and thus the temperature profile, when processing in conduction mode. As for the transition and keyhole regime modeling, heat source parameters or material properties are usually adjusted to make the simulated melt pool dimensions match the real values. This study proposes a novel approach to bypass the conventional heat source calibration strategy to simulate the LBPF process across different melting regimes. The predicted melt pool dimensions are validated for a wide range of process parameters applied to three different alloys: Ti-6Al-4 V, 316 L austenitic stainless steel (316 L), and 2507 super duplex stainless steel (SDSS). The average errors obtained on the melt pool width, depth, length, and aspect ratio are 9.7 %, 12.4 %, 14.5 %, and 14.3 % respectively. These results demonstrate how the proposed approach can capture the melt pool dimensions throughout different materials and melting modes eliminating the time-consuming heat source calibration steps and facilitating the LPBF modeling workflow.