Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy
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 bea...
| Main Authors: | , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2020-09-01
|
| Series: | Materials |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1944/13/18/4157 |
| _version_ | 1797553272234442752 |
|---|---|
| author | Hongyao Shen Jinwen Yan Xiaomiao Niu |
| author_facet | Hongyao Shen Jinwen Yan Xiaomiao Niu |
| author_sort | Hongyao Shen |
| collection | DOAJ |
| description | 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. |
| first_indexed | 2024-03-10T16:14:01Z |
| format | Article |
| id | doaj.art-dc1f968723134581afdc2a7381dec75b |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T16:14:01Z |
| publishDate | 2020-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-dc1f968723134581afdc2a7381dec75b2023-11-20T14:16:19ZengMDPI AGMaterials1996-19442020-09-011318415710.3390/ma13184157Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium AlloyHongyao Shen0Jinwen Yan1Xiaomiao Niu2The State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaThe State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaThe State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, ChinaA 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.https://www.mdpi.com/1996-1944/13/18/4157numerical simulationselective laser meltingAZ91Dmelt poolMarangoni flow |
| spellingShingle | Hongyao Shen Jinwen Yan Xiaomiao Niu Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy Materials numerical simulation selective laser melting AZ91D melt pool Marangoni flow |
| title | Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy |
| title_full | Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy |
| title_fullStr | Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy |
| title_full_unstemmed | Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy |
| title_short | Thermo-Fluid-Dynamic Modeling of the Melt Pool during Selective Laser Melting for AZ91D Magnesium Alloy |
| title_sort | thermo fluid dynamic modeling of the melt pool during selective laser melting for az91d magnesium alloy |
| topic | numerical simulation selective laser melting AZ91D melt pool Marangoni flow |
| url | https://www.mdpi.com/1996-1944/13/18/4157 |
| work_keys_str_mv | AT hongyaoshen thermofluiddynamicmodelingofthemeltpoolduringselectivelasermeltingforaz91dmagnesiumalloy AT jinwenyan thermofluiddynamicmodelingofthemeltpoolduringselectivelasermeltingforaz91dmagnesiumalloy AT xiaomiaoniu thermofluiddynamicmodelingofthemeltpoolduringselectivelasermeltingforaz91dmagnesiumalloy |