Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718
Accumulated spatters not only deteriorate the quality of the built parts in terms of surface roughness and/or density but also sabotage the whole fabrication process via damaging the powder re-coater. A cross-flow of inert gas inside the processing chamber is by far the only effective mean of removi...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2021-11-01
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| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127521006626 |
| _version_ | 1818930857756327936 |
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| author | Cheng-Yen Chien Trong-Nhan Le Ze-Hong Lin Yu-Lung Lo |
| author_facet | Cheng-Yen Chien Trong-Nhan Le Ze-Hong Lin Yu-Lung Lo |
| author_sort | Cheng-Yen Chien |
| collection | DOAJ |
| description | Accumulated spatters not only deteriorate the quality of the built parts in terms of surface roughness and/or density but also sabotage the whole fabrication process via damaging the powder re-coater. A cross-flow of inert gas inside the processing chamber is by far the only effective mean of removing the spouted spatters from the build platform. Despite the essential role, there are few efforts to investigate the interactions between the cross-flow dynamics and the spouted spatters, and hence, to optimize the design and settings of the cross-flow. Therefore, in this study, a coupled computational fluid dynamics (CFD) – discreate element method (DEM) simulation framework is proposed to study the interactions between the flow field and the spouted spatters during the single scan process. The simulation results for the maximum ejection distance and maximum ejection height of the spatters were shown to deviate from the numerical results reported in the literature by no more than 15%. Moreover, the simulation results for the distribution of the landing sites of the spatters were consistent with the experimental observations, which showed that a large number of large spatters landed near the scan track, while a small number of large spatters landed at a greater distance from the scan track. To the best of the authors’ knowledge, this study represents the first reported attempt to use a coupled CFD-DEM simulation framework to investigate the spatter dynamics within an LPBF chamber and to validate the results with experimental observations and published data. The proposed model is an important tool to optimize and calibrate the cross-flow inside the L-PBF processing chamber. |
| first_indexed | 2024-12-20T04:07:22Z |
| format | Article |
| id | doaj.art-dc28f3586dfa4072b0d6d65ddec674f1 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-12-20T04:07:22Z |
| publishDate | 2021-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-dc28f3586dfa4072b0d6d65ddec674f12022-12-21T19:54:00ZengElsevierMaterials & Design0264-12752021-11-01210110107Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718Cheng-Yen Chien0Trong-Nhan Le1Ze-Hong Lin2Yu-Lung Lo3Department of Mechanical Engineering, National Cheng Kung University, Tainan, TaiwanDepartment of Mechanical Engineering, National Cheng Kung University, Tainan, Taiwan; Department of Mechanical Engineering and Product Design Engineering, Swinburne University of Technology, Hawthorn, Melbourne 3122, AustraliaDepartment of Mechanical Engineering, National Cheng Kung University, Tainan, TaiwanDepartment of Mechanical Engineering, National Cheng Kung University, Tainan, Taiwan; Corresponding Author.Accumulated spatters not only deteriorate the quality of the built parts in terms of surface roughness and/or density but also sabotage the whole fabrication process via damaging the powder re-coater. A cross-flow of inert gas inside the processing chamber is by far the only effective mean of removing the spouted spatters from the build platform. Despite the essential role, there are few efforts to investigate the interactions between the cross-flow dynamics and the spouted spatters, and hence, to optimize the design and settings of the cross-flow. Therefore, in this study, a coupled computational fluid dynamics (CFD) – discreate element method (DEM) simulation framework is proposed to study the interactions between the flow field and the spouted spatters during the single scan process. The simulation results for the maximum ejection distance and maximum ejection height of the spatters were shown to deviate from the numerical results reported in the literature by no more than 15%. Moreover, the simulation results for the distribution of the landing sites of the spatters were consistent with the experimental observations, which showed that a large number of large spatters landed near the scan track, while a small number of large spatters landed at a greater distance from the scan track. To the best of the authors’ knowledge, this study represents the first reported attempt to use a coupled CFD-DEM simulation framework to investigate the spatter dynamics within an LPBF chamber and to validate the results with experimental observations and published data. The proposed model is an important tool to optimize and calibrate the cross-flow inside the L-PBF processing chamber.http://www.sciencedirect.com/science/article/pii/S0264127521006626LPBFGas flow measurementSpatter removalCoupled CFD-DEMHigh-speed imaging |
| spellingShingle | Cheng-Yen Chien Trong-Nhan Le Ze-Hong Lin Yu-Lung Lo Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718 Materials & Design LPBF Gas flow measurement Spatter removal Coupled CFD-DEM High-speed imaging |
| title | Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718 |
| title_full | Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718 |
| title_fullStr | Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718 |
| title_full_unstemmed | Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718 |
| title_short | Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718 |
| title_sort | numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of inconel 718 |
| topic | LPBF Gas flow measurement Spatter removal Coupled CFD-DEM High-speed imaging |
| url | http://www.sciencedirect.com/science/article/pii/S0264127521006626 |
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