About this Abstract |
Meeting |
2024 TMS Annual Meeting & Exhibition
|
Symposium
|
Additive Manufacturing Modeling, Simulation and Machine Learning
|
Presentation Title |
A Multi-physics Model for Melt Pool and Keyhole Dynamics in Laser Powder Bed Fusion Process |
Author(s) |
Lichao Fang, Sen Liu, Vivek Thampy, Zane Taylor, Christopher Tassone, Leora Dresselhaus-Marais |
On-Site Speaker (Planned) |
Lichao Fang |
Abstract Scope |
The pores and defects that form in 3D-printed metal parts limit the wide industrial use of metal additive manufacturing (AM). However, the mechanism of keyhole and pores formation and variation are poorly understood. In this work, a multi-physics thermal-fluid-vapor model is developed to predict melt pool and keyhole dynamics during the laser powder bed fusion process for Al6061 material. The thermal-fluid-vapor model is coupled with the discrete element method to account for powders’ effects on melt pool. The model considers liquid-gas surface tracing, powder motion, evaporation, Marangoni effects, surface tension, recoil pressure, phase change and laser-material interaction. Predicted melt pool and keyhole dynamics are shown to agree well with in-situ ultra-fast X-ray videos from experiments with different laser parameters. The melt pool flow, keyhole and bubble motions for varied laser parameters are compared and analyzed, which can guide metal additive manufacturing process design. |
Proceedings Inclusion? |
Planned: |
Keywords |
Additive Manufacturing, Computational Materials Science & Engineering, Modeling and Simulation |