Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy
Low performance is considered one of the main drawbacks of laser powder bed fusion (LPBF) technology. In the present work, the effect of the AlSi10Mg powder layer thickness on the laser melting process was investigated to improve the LPBF building rate. A high-fidelity simulation of the melt pool fo...
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| Format: | Article |
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MDPI AG
2024-01-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/8/1/7 |
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| author | Maria Bogdanova Stanislav Chernyshikhin Andrey Zakirov Boris Zotov Leonid Fedorenko Sergei Belousov Anastasia Perepelkina Boris Korneev Maria Lyange Ivan Pelevin Inna Iskandarova Ella Dzidziguri Boris Potapkin Alexander Gromov |
| author_facet | Maria Bogdanova Stanislav Chernyshikhin Andrey Zakirov Boris Zotov Leonid Fedorenko Sergei Belousov Anastasia Perepelkina Boris Korneev Maria Lyange Ivan Pelevin Inna Iskandarova Ella Dzidziguri Boris Potapkin Alexander Gromov |
| author_sort | Maria Bogdanova |
| collection | DOAJ |
| description | Low performance is considered one of the main drawbacks of laser powder bed fusion (LPBF) technology. In the present work, the effect of the AlSi10Mg powder layer thickness on the laser melting process was investigated to improve the LPBF building rate. A high-fidelity simulation of the melt pool formation was performed for different thicknesses of the powder bed using the Kintech Simulation Software for Additive Manufacturing (KiSSAM, version cd8e01d) developed by the authors. The powder bed after the recoating operation was obtained by the discrete element method. The laser energy deposition on the powder particles and the substrate was simulated by ray tracing. For the validation of the model, an experimental analysis of single tracks was performed on two types of substrates. The first substrate was manufactured directly with LPBF technology, while the second was cast. The simulation was carried out for various combinations of process parameters, predominantly with a high energy input, which provided a sufficient remelting depth. The calculations revealed the unstable keyhole mode appearance associated with the low absorptivity of the aluminum alloy at a scanning speed of 300 mm/s for all levels of the laser power (325–375 W). The results allowed formulating the criteria for the lack of fusion emerging during LPBF with an increased layer thickness. This work is expected to provide a scientific basis for the analysis of the maximum layer thickness via simulation to increase the performance of the technology. |
| first_indexed | 2024-03-07T22:26:55Z |
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| id | doaj.art-af3af17b9cf245dbb46e06d43c2abd3e |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-07T22:26:55Z |
| publishDate | 2024-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-af3af17b9cf245dbb46e06d43c2abd3e2024-02-23T15:22:50ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-01-0181710.3390/jmmp8010007Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg AlloyMaria Bogdanova0Stanislav Chernyshikhin1Andrey Zakirov2Boris Zotov3Leonid Fedorenko4Sergei Belousov5Anastasia Perepelkina6Boris Korneev7Maria Lyange8Ivan Pelevin9Inna Iskandarova10Ella Dzidziguri11Boris Potapkin12Alexander Gromov13Kintech Lab Ltd., 3rd Khoroshevskaya St. 12, 123298 Moscow, RussiaCatalysis Lab, National University of Science and Technology MISIS, Leninskiy Prospekt 4, 119049 Moscow, RussiaKintech Lab Ltd., 3rd Khoroshevskaya St. 12, 123298 Moscow, RussiaCatalysis Lab, National University of Science and Technology MISIS, Leninskiy Prospekt 4, 119049 Moscow, RussiaCatalysis Lab, National University of Science and Technology MISIS, Leninskiy Prospekt 4, 119049 Moscow, RussiaKintech Lab Ltd., 3rd Khoroshevskaya St. 12, 123298 Moscow, RussiaKintech Lab Ltd., 3rd Khoroshevskaya St. 12, 123298 Moscow, RussiaKintech Lab Ltd., 3rd Khoroshevskaya St. 12, 123298 Moscow, RussiaCatalysis Lab, National University of Science and Technology MISIS, Leninskiy Prospekt 4, 119049 Moscow, RussiaCatalysis Lab, National University of Science and Technology MISIS, Leninskiy Prospekt 4, 119049 Moscow, RussiaKintech Lab Ltd., 3rd Khoroshevskaya St. 12, 123298 Moscow, RussiaCatalysis Lab, National University of Science and Technology MISIS, Leninskiy Prospekt 4, 119049 Moscow, RussiaKintech Lab Ltd., 3rd Khoroshevskaya St. 12, 123298 Moscow, RussiaCatalysis Lab, National University of Science and Technology MISIS, Leninskiy Prospekt 4, 119049 Moscow, RussiaLow performance is considered one of the main drawbacks of laser powder bed fusion (LPBF) technology. In the present work, the effect of the AlSi10Mg powder layer thickness on the laser melting process was investigated to improve the LPBF building rate. A high-fidelity simulation of the melt pool formation was performed for different thicknesses of the powder bed using the Kintech Simulation Software for Additive Manufacturing (KiSSAM, version cd8e01d) developed by the authors. The powder bed after the recoating operation was obtained by the discrete element method. The laser energy deposition on the powder particles and the substrate was simulated by ray tracing. For the validation of the model, an experimental analysis of single tracks was performed on two types of substrates. The first substrate was manufactured directly with LPBF technology, while the second was cast. The simulation was carried out for various combinations of process parameters, predominantly with a high energy input, which provided a sufficient remelting depth. The calculations revealed the unstable keyhole mode appearance associated with the low absorptivity of the aluminum alloy at a scanning speed of 300 mm/s for all levels of the laser power (325–375 W). The results allowed formulating the criteria for the lack of fusion emerging during LPBF with an increased layer thickness. This work is expected to provide a scientific basis for the analysis of the maximum layer thickness via simulation to increase the performance of the technology.https://www.mdpi.com/2504-4494/8/1/7building rateLPBFmesoscale simulation LBMperformance GPUAlSi10Mglayer thickness |
| spellingShingle | Maria Bogdanova Stanislav Chernyshikhin Andrey Zakirov Boris Zotov Leonid Fedorenko Sergei Belousov Anastasia Perepelkina Boris Korneev Maria Lyange Ivan Pelevin Inna Iskandarova Ella Dzidziguri Boris Potapkin Alexander Gromov Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy Journal of Manufacturing and Materials Processing building rate LPBF mesoscale simulation LBM performance GPU AlSi10Mg layer thickness |
| title | Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy |
| title_full | Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy |
| title_fullStr | Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy |
| title_full_unstemmed | Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy |
| title_short | Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy |
| title_sort | mesoscale simulation of laser powder bed fusion with an increased layer thickness for alsi10mg alloy |
| topic | building rate LPBF mesoscale simulation LBM performance GPU AlSi10Mg layer thickness |
| url | https://www.mdpi.com/2504-4494/8/1/7 |
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