Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis
Laser aided additive manufacturing (LAAM), a blown powder additive manufacturing process, can be widely adopted for surface modification, repair and 3D printing. A robust numerical model was developed to simulate convective fluid flow and balancing of surface tension forces at the air-fluid interfac...
| Main Authors: | , , , , , , |
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| Other Authors: | |
| Format: | Journal Article |
| Language: | English |
| Published: |
2020
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| Subjects: | |
| Online Access: | https://hdl.handle.net/10356/142414 |
| _version_ | 1811677197031702528 |
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| author | Song, Jie Chew, Youxiang Bi, Guijun Yao, Xiling Zhang, Baicheng Bai, Jiaming Moon, Seung Ki |
| author2 | School of Mechanical and Aerospace Engineering |
| author_facet | School of Mechanical and Aerospace Engineering Song, Jie Chew, Youxiang Bi, Guijun Yao, Xiling Zhang, Baicheng Bai, Jiaming Moon, Seung Ki |
| author_sort | Song, Jie |
| collection | NTU |
| description | Laser aided additive manufacturing (LAAM), a blown powder additive manufacturing process, can be widely adopted for surface modification, repair and 3D printing. A robust numerical model was developed to simulate convective fluid flow and balancing of surface tension forces at the air-fluid interface to predict melt-pool free surface curvature and solidified clad dimensions. The free surface physical interface was calculated using the Arbitrary Lagrangian Eulerian (ALE) moving mesh approach. Powder deposition efficiency was considered by activating mesh normal velocity at melted regions based on localized powder mass flux intensity from the discrete coaxial powder nozzles. The heat flux equation used for representing the laser heat source considered attenuation effect from the interaction between the powder jets and laser as well as heat sink effects of un-melted powder particles entering the melt-pool. The predicted thermal gradient directions agree well with grain growth orientations obtained from electron backscatter diffraction (ESBD) analysis in three different cross-sectional orientations. Experimental validation of clad width, height and melt-pool depth shows a maximum error of 10% for a wide range of processing parameters which consider the effects of varying laser power, laser scanning speed and powder feeding rate. |
| first_indexed | 2024-10-01T02:33:32Z |
| format | Journal Article |
| id | ntu-10356/142414 |
| institution | Nanyang Technological University |
| language | English |
| last_indexed | 2024-10-01T02:33:32Z |
| publishDate | 2020 |
| record_format | dspace |
| spelling | ntu-10356/1424142020-06-22T03:10:44Z Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis Song, Jie Chew, Youxiang Bi, Guijun Yao, Xiling Zhang, Baicheng Bai, Jiaming Moon, Seung Ki School of Mechanical and Aerospace Engineering Engineering::Mechanical engineering Laser Aided Additive Manufacturing Numerical Simulation Laser aided additive manufacturing (LAAM), a blown powder additive manufacturing process, can be widely adopted for surface modification, repair and 3D printing. A robust numerical model was developed to simulate convective fluid flow and balancing of surface tension forces at the air-fluid interface to predict melt-pool free surface curvature and solidified clad dimensions. The free surface physical interface was calculated using the Arbitrary Lagrangian Eulerian (ALE) moving mesh approach. Powder deposition efficiency was considered by activating mesh normal velocity at melted regions based on localized powder mass flux intensity from the discrete coaxial powder nozzles. The heat flux equation used for representing the laser heat source considered attenuation effect from the interaction between the powder jets and laser as well as heat sink effects of un-melted powder particles entering the melt-pool. The predicted thermal gradient directions agree well with grain growth orientations obtained from electron backscatter diffraction (ESBD) analysis in three different cross-sectional orientations. Experimental validation of clad width, height and melt-pool depth shows a maximum error of 10% for a wide range of processing parameters which consider the effects of varying laser power, laser scanning speed and powder feeding rate. ASTAR (Agency for Sci., Tech. and Research, S’pore) 2020-06-22T03:10:44Z 2020-06-22T03:10:44Z 2018 Journal Article Song, J., Chew, Y., Bi, G., Yao, X., Zhang, B., Bai, J., & Moon, S. K. (2018). Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis. Materials and Design, 137, 286-297. doi:10.1016/j.matdes.2017.10.033 0261-3069 https://hdl.handle.net/10356/142414 10.1016/j.matdes.2017.10.033 2-s2.0-85031800880 137 286 297 en Materials and Design © 2017 Elsevier Ltd. All rights reserved. |
| spellingShingle | Engineering::Mechanical engineering Laser Aided Additive Manufacturing Numerical Simulation Song, Jie Chew, Youxiang Bi, Guijun Yao, Xiling Zhang, Baicheng Bai, Jiaming Moon, Seung Ki Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis |
| title | Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis |
| title_full | Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis |
| title_fullStr | Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis |
| title_full_unstemmed | Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis |
| title_short | Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis |
| title_sort | numerical and experimental study of laser aided additive manufacturing for melt pool profile and grain orientation analysis |
| topic | Engineering::Mechanical engineering Laser Aided Additive Manufacturing Numerical Simulation |
| url | https://hdl.handle.net/10356/142414 |
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