Pool Evolution Research Articles

Analysis of melt pool evolution, defect mechanisms, and grain growth of Inconel 625 formers in selective laser melting

In this study, we integrate the discrete element method, computational fluid dynamics, and cellular automata models to simulate and analyze the transient variations in temperature and velocity fields, various process defect mechanisms, and the grain growth process during solidification in the selective laser melting (SLM) process. Our goal is to derive optimal process parameters and compare the experimental results with those from simulation. The simulations reveal that low energy density leads to spheroidization defects, pore defects, and single-pass unevenness, whereas high energy density results in spatter and single-pass unevenness defects. These can be mitigated by controlling the process parameters, thus enhancing the surface quality of the formed part. By examining grain growth at different stages and orientations, we analyzed epitaxial growth driven by the temperature gradient and competitive growth due to internal flow, which generates new grains. Ultimately, we experimentally analyzed the mechanical properties, physical phases, grain characteristics, surface morphology, and fracture morphology of the Inconel 625 part under suitable process parameters. This comprehensive analysis of single-pass forming by SLM provides a reference for selecting process parameters in production and understanding changes in the melt pool, defect mechanisms, and grain characteristics throughout the research process.

Track trajectory, molten pool and defect characterization in NiTi single-track selective laser melting (SLM) experiments

In order to explore the law of selective laser melting (SLM) forming of Nitinol alloy, and obtain high quality additive manufacturing parameters of Nitinol alloy, a series of single-track SLM experiments on Nitinol alloy were conducted under different combined parameters of laser power and scanning speed. The effects of laser power, scanning speed and linear energy density on track forming, molten pool evolution and pore formation were systematically discussed by characterizing the track trajectory, molten pool morphology, dimensions and defects of the molten pool, and the ideal process parameters were obtained. The experimental results revealed that the average track width and width uniformity decreased with the increase of the scanning speed, the spheroidization phenomenon and height fluctuation became more pronounced, and the phenomena of necking, subsection and interruption increased significantly at the fixed laser power. Under the fixed scanning speed, the width, height and width uniformity of the molten track gradually increased with the increase of the laser power, and the phenomena of spheroidization, subsection and interruption gradually reduced. Moreover, the upper zone of the molten pool is shaped like an inverted bowl, and the lower zone is mainly divided into five categories, which are lack of fusion, shallow bowl shape, deep bowl shape, keyhole shape and deeper keyhole shape under different process parameters. The defects of the molten pool mainly include lack of fusion and trapped gas. An ideal molten pool without defects can be obtained under the parameter conditions of 100–150W laser power and 100–200 mm/s spanning speed.

Beyond symmetry: Investigating asymmetric melt pool evolution in multi-pulse laser surface melting

A numerical investigation is carried out to explore the intricacies of multi-pulse pulsed laser surface melting (pLSM) to understand its impact on surface evolution. A finite-element-based multi-phase model with temperature-dependent properties is employed to track the interface for multiple laser pulses. Examining various overlap spacings and conducting a comparative analysis of the number of pulses, the study focuses on the exclusive influence of overlapping in surface texture generation. Notably, the assumption of an initially flat surface eliminates the effects of the initial surface roughness to provide unique insights completely based on multi-pulse dynamics. While the first pulse on a flat initial surface resulted in a symmetric surface evolution, asymmetric melt pools were observed in the second pulse and subsequent pulses. The asymmetry results from non-uniform cooling and melt pool flows influenced by the surface evolved in the first pulse. The topography-driven surface tension from the first pulse made the trailing peak solidify slower than the leading peak. The asymmetry was significant for smaller overlaps between the two pulses and reduced as the overlap increased. Further, an increase in the number of laser pulses promotes the generation of identical asymmetric surface features. In conclusion, the study demonstrates the importance of the developed model in accurately predicting the surface evolution influenced by topography-driven surface tension and that single pulse axisymmetric models are insufficient.

Computational modeling of multi-track multi-layer laser directed energy deposition process

This study presents the development of a 3D fully coupled thermomechanical finite element model to evaluate the melt pool geometry, defects, and micro-hardness of multi-track multi-layer deposition in the powder feed laser-directed energy deposition (LDED) technique. Fabrication strategies can significantly affect the melt pool geometry and material behavior of the manufactured components. Understanding the effect of process parameters in a multi-track multi-layer LDED is important. Optimal process parameters are crucial for achieving high-quality deposition in terms of deposition geometry and integrity. The model can aid in mitigating issues such as inadequate inter-track or track-substrate fusion, porosity, cracks, and other defects. A multi-track multi-layer finite element model (FEM) can realistically predict melt pool evolution, mechanical properties, and defects in laser-LDED. This work focuses on the development of a fully coupled thermomechanical model for multi-track multi-layer deposition processes using ABAQUS®. The finite element framework employs Johnson-Cook’s flow stress model for constitutive behavior and the Koistein-Marburger equation for predicting hardness. Two tracks and two layers of SS316L powder are deposited on an SS304 substrate in finite element simulations and experiments. The model has been validated for the melt-pool depth in the substrate, deposition geometry, heat-affected zone, and hardness. It has been observed that there is a ∼10 % error in the prediction of melt pool geometry characterization and a ∼12 % error in hardness as compared to experimental results. The melt-pool width, depth, substrate dilution, and hardness have been characterized as a function of process parameters via simulations and experiments. The model is capable of predicting inter-track and interface defects. In addition, the effect of interlayer cooling on the melt-pool geometry and hardness has been studied.

A Scan Strategy Based Compensation of Cumulative Heating Effects in Electron Beam Powder Bed Fusion

AbstractThe fabrication of complex geometries with uniform material properties in electron beam powder bed fusion (PBF-EB) remains a major challenge. Local material properties in PBF-EB are determined by the local thermal conditions and the spatio-temporal melt pool evolution. The local thermal conditions are governed by the cumulative heating effect on the hatch scale, which results from the superposition of temperature fields from adjacent hatch lines. The build-up of the cumulative heating effect at the beginning of a new hatch segment, without prior hatch lines, which results in regions with underdeveloped thermal conditions, is so far only rarely considered in the design of process strategies. This study introduces a numerical optimization scheme with the objective to minimize the extent of regions with underdeveloped thermal conditions at the beginning of line-based hatches, by means of scan strategy modifications. For this purpose, a simplified thermal solution is combined with an optimization approach to determine an optimal process strategy for line-based PBF-EB of a cuboid model geometry through the adaptation of individual hatch line spacing. Based on the approach determined for the model geometry, a generalized process strategy is derived for complex geometries and is numerically validated for different process parameter and geometry combinations.

Integrated framework of multi−physics mechanism models for gas−powder flow, molten pool evolution and part deformation in high alloy steel additive manufacturing process

Multi−physics numerical models for metal additive manufacturing (MAM) could replace the expensive trial−and−error experiments, reveal the mechanisms of printing process, and provide an effective means of optimizing process parameters and mitigating part defects. However, the existing simulations of MAM process seldom consider the coupling effects between multiple recursive processes. There is an urgent need to overcome the dilemma of limiting MAM process simulation to a localized single sub−process. For directed energy deposition (DED) additive manufacturing process, the integrated simulation framework proposed in this study consists of a gas−powder flow model, a heat and fluid flow model, and a sequentially coupled thermal–mechanical model, which can be used to predict the feedstock feeding process, the evolution of molten pool, and the residual deformations of metal part, respectively. The accurate results of the three recursive sub−processes can be obtained by delivering the validated parameters between models. Corresponding experiments are conducted to verify the accuracy of the integrated framework based on 12CrNi2 alloy powders. The deviation of the predicted focal distance of powder streams is 5.14 %, and the deviations of the predicted molten pool height and width are all less than 8.5 %. The integrated framework could rapidly and accurately predict the residual deformation tendency and the position where the maximum deformation occurs. For single−track and eight−layer line deposition, the deviations of the predicted maximum deformation are all within 0.1 mm. The integrated framework could efficiently provide accurate and comprehensive solutions for optimizing DED process.

Microstructure forming mechanism of inconel 625 alloy fabricated by laser/ultra-high (UHF) induction hybrid deposition method

To reveal the microstructure forming mechanism of laser/ultra-high frequency (UHF) induction deposition, this paper developed a microscopic phase-field (PF) model to numerically investigate dendrite growth during solidification. The macroscopic model of molten pool evolution is adopted to provide the solidification conditions for the microscopic PF model. The dendrite growth during laser deposition is simulated to evaluate the effect of UHF induction heat on the dendrite growth. Results show that because of the high temperature gradient and cooling rate, the PDAS of laser-UHF induction hybrid deposited layer is less than that of the laser deposited layer. The UHF induction heat also leads to a high flow velocity of the molten metal during laser-UHF induction hybrid deposition. The high flow velocity contributes to the decrease in PDAS by inhibiting the interdendritic enrichment of solute. During laser-UHF induction hybrid deposition, a higher solute gradient is present in the tip region of dendrite arm, leading to a faster dendrite growth rate. The UHF induction heat also increases the solute distribution coefficient during deposition, which further inhibits the element segregation. Under the action of UHF induction heat, a low interdendritic solute gradient and an evenly distributed solute can be obtained, thus helping increase interdendritic undercooling degrees and decreasing the PDAS. The simulated PDAS and solute distribution have good consistency with the experimental results. The spectral analysis of EDS line detection indicates that the laser-UHF induction hybrid deposited layer has a more refined microstructure and weaker element segregation than the laser deposited layer does.

Laser contacting of hairpin windings in electrical vehicle motors using ring-mode laser beams based on angularly-uniform Lissajous trajectories.

The contacting process of hairpin windings is deemed the most important and challenging process in manufacturing electric vehicle motors. This paper proposes a ring-mode laser contacting method for copper hairpin windings based on Lissajous-shaped cyclic scanning with a uniform angular speed. Two key variables, trajectory cycle n and angular multiplier k, which represent the laser energy input and distribution respectively, were investigated via single-factor experiments. Morphology, microstructure, mechanical and electrical properties were analyzed consequentially to show the influence on the contact quality. The results show that, as n increases, contact appearance is criticized for being under-contacted, well-contacted, or over-contacted. Molten pool behaviors affected by n variations determine morphology formation. Larger k facilitates molten pool evolution and improves laser contacting efficiency. Fusion zone (FZ) has directional columnar grains, while heat-affected zone (HAZ) has overgrown equiaxed grains coarser than those of base metal (BM). The microstructure of FZ becomes coarser if n increases, or finer if k increases. The highest tensile force of 712.5 N was reached when k = 4, n = 6. Ductile dimple fractures in FZ indicate the contacts' excellent strength and toughness. FZ and HAZ show lower microhardness than BM due to thermal softening. FZ is slightly harder than HAZ due to its densely-interlaced microstructure. Poor contacts cause reduction in their electrical conductivity and increase in their resistance.

Numerical simulation and experimental investigation of the molten pool evolution and defects formation mechanism of Selective laser melted CuSn20/Diamond composites

Some defects such as small pores, thermal damage of diamond particle and micro-cracks between diamond and metal matrix existed in SLM-fabricated metal-bonded diamond tools. For further application, it is vital to understand the formation mechanism of such defects by SLM-fabricated parameters. In this work, a multiphysics field numerical simulation model based on computational fluid dynamics (CFD) was developed to investigate molten pool evolution and defects formation mechanism for SLM-fabricated CuSn20-bonded diamond composites. From simulation results, the metal particles melt and flow forward under the action of the laser. Also, the presence of diamond particles can obstruct the normal flow of melted CuSn20 fluid. Increasing the laser power can widen and stabilize the molten pool, however, exacerbate the thermal damage of diamond particles. Specially, the migration and marginalisation of the diamond particles during the formation of molten pool were found by simulation and experimental results. Unavoidably, there are obvious gaps in the interfacial bonding region of diamond and CuSn20 due to the comprehensive reasons of thermal gradient, differences in thermophysical properties of two materials and undergo continuous migration and rotational behavior of diamond particles. These findings have potential value for understanding and optimizing the process of SLM-fabricated metal-bonded diamond tools.

Brittle faulting and tectonic stress history on the western margin of the Congo Basin between Kinshasa and Brazzaville: Implications for the evolution of the Malebo Pool and the Congo River

The history of brittle faulting and associated paleostress states has been investigated in the rapids of the Congo River at the outlet of the Malebo Pool between Kinshasa (Democratic Republic of the Congo) and Brazzaville (Republic of the Congo). The aim of this study was to unravel the Meso-Cenozoic tectonic evolution of the western margin of Central Africa, as well as to investigate the dynamic evolution of the Pool and the capture of the Congo Basin drainage system by the Lower Congo River through the Central African Atlantic swell that formed between the Congo Basin and the Atlantic Ocean. We reviewed the geological evolution of the Pool area using recent data and new field observations to develop a consistent stratigraphic model for both sides of the Congo River. We collected a significant amount of data faults and fractures in the early Paleozoic Inkisi arkosic sandstones, identified four successive data subsets and determined their related paleostress tensors trough an iterative process utilizing relative chronological indications. All paleostress states exhibit a a strike-slip faulting regime, with varying orientation of horizontal principal compression. The timing of faulting was constrained by indirect observations based on the updated understanding of the Pool's evolution. The geodynamic interpretation of the brittle stages considered potential sources of compressional stress arising from plate boundaries and from the oceanic ridge push. A polyphase brittle tectonic history was identified, characterized by the gradual appearance of newly formed faults and reactivation of the existing ones, leading to the gradual saturation of the host rock with fractures. The most recent event let to a significant imprint on the current landscape and is believed to have facilitated the connection of the drainage system of the Congo Basin to the Atlantic coast in the Oligocene period. The current stress state, determined from earthquake focal mechanisms, aligns with the most recent paleostress state identified determined from fault-slip data, displaying similar stress axis orientations but with consistent with a transpressional stress regime instead of a strike-slip one.

How Variable Are Cold Pools?

AbstractCold pools formed by precipitating convective clouds are an important source of mesoscale temperature variability. However, their sub‐mesoscale (100 m–10 km) structure has not been quantified, impeding validation of numerical models and understanding of their atmospheric and societal impacts. We assess temperature variability in observed and simulated cold pools using variograms calculated from dense network observations collected during a field experiment and in high‐resolution case‐study and idealized simulations. The temperature variance in cold pools is enhanced for spatial scales between ∼5 and 15 km compared to pre‐cold pool conditions, but the magnitude varies strongly with cold pool evolution and environment. Simulations capture the overall cold pool variogram shape well but underestimate the magnitude of the variability, irrespective of model resolution. Temperature variograms outside of cold pool periods are represented by the range of simulations evaluated here, suggesting that models misrepresent cold pool formation and/or dissipation processes.

Investigation of thermal behavior of powder stream and molten pool during laser-based directed energy deposition

Laser-powder interaction and molten pool evolution are two main physical processes in laser-based directed energy deposition (L-DED), which greatly affect the morphology and quality of the deposition layer. In this research, a comprehensive three-dimensional analytical-numerical model which integrates a laser-powder interaction model and material deposition model is developed to study the multi-physics coupling characteristics in L-DED process. The concentration of the powder stream is modeled based on conservation of mass and is in good agreement with the experimental result which is captured by high-speed camera. The effects of main parameters, including laser power, powder feeding rate, powder feeding angle and defocus length on the laser attenuation and the temperature distribution of the in-flight powder particles are analyzed. The results show that the laser attenuation rate increases from 0.72% to 1.36% with the powder feeding angle increasing from 45 deg. to 65 deg-. However, the laser attenuation rate is almost the same with the defocus length of 25 mm, 35 mm and 45 mm. Moreover, the peak powder temperature on the deposition surface increases with the increase of powder feeding angle and decrease of defocus length. Accordingly, the heat and mass input conditions at the molten pool surface for the material deposition model, including powder mass flux, effective laser intensity and powder temperature are obtained from the laser-powder interaction model. The heat transport and fluid dynamics of the molten pool are discussed based on the calculated results from material deposition model. Finally, the calculated molten pool geometry shows good agreement with the experimental results with the relative error <8.5%. This work is helpful in process optimization from the point of view of adjusting the parameters related to the powder stream and deeper understanding of laser-powder interaction and molten pool evolution during the L-DED process.

Numerical investigation of the melt pool geometry evolution during selective laser melting of 316L SS

In this study, the melt pool size, precisely its width and depth, are numerically investigated for a wide range of values for both laser power and beam speed. A thermal model, developed on Ansys Additive Science, simulates the SLM of a single bead. A parametric study is achieved aiming at understanding the melt pool evolution and the defects appearing while varying these two parameters. The discussed porosity defects, namely the LOF and keyhole, are determined using the calculated melt pool dimensions and through mathematical correlations from the literature. Moreover, these numerical results are validated with experimental results for the reliability of the study. This investigation reveals a proportional relationship between the melt pool size and the laser power and an inversely proportional relationship with the scan speed. The optimal combination of these two parameters has to be well studied to avoid LOF and keyhole, which is afforded by this paper. At lower laser power levels, such as 100 W, it is advisable to choose a slower scan speed ranging from 400 to 500 mm/s. As the laser power increases, so does the optimal scan speed. For instance, with 150 W, the ideal speed falls between 600 to 900 mm/s. Similarly, for 200 W, the recommended scan speed range extends from 900 to 1200 mm/s, and for 250 W, the optimal speed range lies between 1100 and 1400 mm/s.

Thermodynamic study of molten pool during selective laser melting of alsi10mg alloy

A study of the thermodynamic behavior during the Selective Laser Melting process of AlSi10Mg alloy was conducted using a combined numerical simulation and experimental approach. A multiphase flow model incorporating gas-liquid-solid phases was established. The numerical simulation results aligned well with experimental findings, affirming the reliability of the numerical model. Insufficient and excessive laser power densities respectively led to incomplete fusion defects and spherical pore defects. The evolution of the melt pool was primarily influenced by recoil pressure, Marangoni force, and surface tension, resulting in keyhole formation, convective flow, and liquid surface oscillation as characteristic features of melt pool evolution. Solidification process and mechanical analyses revealed that the central region of the melt pool exhibited smaller temperature gradients and higher solidification rates. Properly increasing the scanning speed under suitable laser power conditions is more conducive to optimizing the solidification structure and enhancing the mechanical properties of SLM components. This study elucidates the thermodynamic evolution mechanism during the SLM process of aluminum-based alloys, providing theoretical support and guidance for optimizing the SLM process.

Dynamics of molten pool evolution and high-speed real-time optical measurement in laser polishing

Dynamics of molten pool evolution and high-speed real-time optical measurement in laser polishing

Comparative Analysis of Melt Pool Evolution in Selective Laser Melting of Inconel 625 and Inconel 718 Nickel-Based Superalloys

One of the key advantages of Additive Manufacturing is the versatility in working with a wide range of materials. Among these materials, Nickel-based superalloys have drawn great attention of specialists. This study investigates the behavior of Inconel 625 and Inconel 718 during selective laser melting. While these alloys have many similarities, thus their distinct chemical compositions determine different responses to this new process, which the authors aimed to elucidate in this study. Numerical simulations using ANSYS Additive® software were conducted to compare the melt pool dimensions (depth and width) of Inconel 625 and Inconel 718. The results reveal that the material's thermal properties play a significant role in determining the melt pool geometry. The Inconel 718 consistently exhibited larger melt pool dimensions than Inconel 625. The findings highlight the importance of understanding the connection between the material properties and process parameters.

Melt pool evolution and microstructure simulation of SLM 316L based on SPH-PFM coupling model

The study in this work fully utilized the computational advantages of various numerical methods and established a SPH-PFM coupling model for the 316 L SLM process. The temperature field, melt pool changes, and microstructure evolution of the 316 L SLM process were simulated and calculated. The correctness of the simulation results was verified through the comparison with experiments, and a calculation platform for melt pool evolution and microstructure simulation of metal material SLM process with independent intellectual property rights was developed. (1) Establish the mathematical model required for the dynamic simulation of the molten pool in the metal material SLM process based on the SPH method. (2) Extract the temperature field data and molten pool shape from the calculation results based on the SPH method, and then substitute them into the phase field model for molten pool modeling. The formation mechanism of the microstructure morphology inside the molten pool and the micro-segregation mechanism of solute elements at different positions during solidification were analyzed and discussed. The article compared the simulation results with the experimental results. The simulation results showed good consistency with the experimental results in terms of primary dendrite spacing, secondary dendrite spacing, and melt pool microstructure morphology, proving the correctness of the model established in this article. At the same time, the SPH-PFM coupling model established in this article can effectively solve the problem of predicting the microstructure of the melt pool in the SLM process, providing a new method for the study of microstructure prediction in the SLM process.

The effect of molten pool evolution on the formation of surface structures during laser polishing

As a novel surface treatment technology, in-situ laser polishing aims to improve surface finish of 3D printed parts, while laying the foundation for the integrated processing of 3D printing and laser polishing. However, the polishing process will introduce a few new surface structures (undercuts, step structures, ripples, etc.), which will affect the surface roughness. In this work, the surface roughness and surface structure after high power and low power polishing were compared respectively through experiments. In addition, a 2D transient numerical model was developed to explore the forming mechanism of different structures. The evolution of temperature field, velocity field and freedom surface of melting pool under different parameters were analyzed by the model. The results showed that the solidification induced surface structure with large roughness was generated after high power polishing. During its formation, the thermocapillary force was dominant and drove the tangential flow of fluid. While, low power polishing resulted in ripple structure with small roughness. The emergence of this structure was primarily due to the capillary force as the leading force in the melting pool flow process, which drove the normal flow of the melt, thus eliminating the large surface curvature. Furthermore, the width of the melting pool in the simulation was compared with the width of the single scanning track, and they were in good agreement. Finally, by adjusting the test strategy, it was found that the surface roughness could reach the lowest (0.88 ± 0.06 μm) only when the two structures coexisted.

Overlap between the Mid-Atlantic Bight Cold Pool and offshore wind lease areas

AbstractThe Mid-Atlantic Cold Pool is a seasonal mass of cold bottom water that extends throughout the Mid-Atlantic Bight (MAB). Formed from rapid vernal surface warming, the Cold Pool dissipates in the fall due to mixing events such as storms. The Cold Pool supports a myriad of MAB coastal ecosystems and economically valuable commercial and recreational fisheries. Offshore wind energy has been rapidly developing within the MAB in recent years. Studies in Europe demonstrate that offshore wind farms can impact ocean mixing and hence seasonal stratification; there is, however, limited information on how MAB wind development will affect the Cold Pool. Seasonal overlap between the Cold Pool and pre-construction wind lease areas at varying distances from shore in the MAB was evaluated using output from a data-assimilative ocean model. Results highlight overlap periods as well as a thermal gradient that persists after bottom temperatures warm above the threshold typically used to identify the Cold Pool. These results also demonstrate cross-shelf variability in Cold Pool evolution. This work highlights the need for more focused ocean modeling studies and observations of wind farm effects on the MAB coastal environment.

In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition

The presence of defects, such as pores, in materials processed using additive manufacturing represents a challenge during the manufacturing of many engineering components. Recently, ultrasonic vibration-assisted (UV-A) directed energy deposition (DED) has been shown to reduce porosity, promote grain refinement, and enhance mechanical performance in metal components. Whereas it is evident that the formation of such microstructural features is affected by the melt pool behavior, the specific mechanisms by which ultrasonic vibration (UV) influences the melt pool remain elusive. In the present investigation, UV was applied in situ to DED of 316L stainless steel single tracks and bulk parts. For the first time, high-speed video imaging and thermal imaging were implemented in situ to quantitatively correlate the application of UV to melt pool evolution in DED. Extensive imaging data were coupled with in-depth microstructural characterization to develop a statistically robust dataset describing the observed phenomena. Our findings show that UV increases the melt pool peak temperature and dimensions, while improving the wettability of injected particles with the melt pool surface and reducing particle residence time. Near the substrate, we observe that UV results in a 92% decrease in porosity, and a 54% decrease in dendritic arm spacing. The effect of UV on the melt pool is caused by the combined mechanisms of acoustic cavitation, ultrasound absorption, and acoustic streaming. Through in situ imaging we demonstrate quantitatively that these phenomena, acting simultaneously, effectively diminish with increasing build height and size due to acoustic attenuation, consequently decreasing the positive effect of implementing UV-A DED. Thus, this research provides valuable insight into the value of in situ imaging, as well as the effects of UV on DED melt pool dynamics, the stochastic interactions between the melt pool and incoming powder particles, and the limitations of build geometry on the UV-A DED technique.