Surface roughness and pore evolutions in multi-layer laser powder bed fusion of extra-low interstitial Ti-5Al-2.5Sn powder: A numerical study

doi:10.1016/j.addma.2024.104530

IMR OpenIR

	Surface roughness and pore evolutions in multi-layer laser powder bed fusion of extra-low interstitial Ti-5Al-2.5Sn powder: A numerical study
	Long, Yifu 1; An, Xizhong 1; Wang, Ju 1; Li, Meng 1; Wu, Qiong 1; Jiang, Chuanning 1; Liu, Junfei 1; Ren, Dechun 2; Ji, Haibin 2; Li, Shujun 2; Zhang, Xing 2
通讯作者	An, Xizhong(anxz@mail.neu.edu.cn)
	2024-09-05
发表期刊	ADDITIVE MANUFACTURING
ISSN	2214-8604
卷号	95 页码:21
摘要	In this paper, the three-dimensional discrete element method (DEM) and computational fluid dynamics (CFD) coupled approach was used to numerically reproduce the whole process of laser powder-bed-fusion (L-PBF) additive manufacturing (AM) of extra-low interstitial (ELI) Ti-5Al-2.5Sn powder. The effects of key parameters such as scanning strategy and hatch spacing (h) on the surface roughness (Ra) and pores during multi-layer printing are systematically investigated by characterizing the molten pool characteristics and thermal behavior upon laser motion; and the melt volume in this duration is quantified by the volume of fluid (VOF) method to demonstrate inter-layer interactions. The results show that Ra can be categorized according to the scanning directions. Along the scanning direction, the Ra is affected by the heat accumulation effect and increases as the h decreases. In this case, the Ra caused by the Marangoni effect can be reduced by increasing the melt volume at the end of the track through the layer rotation. The Ra perpendicular to the scanning direction is caused by the ripple-like surface formed by track overlap and decreases as the h decreases. For defects, the pores formed by shrinkage due to insufficient melting or by lack of fusion (LoF) due to incomplete track overlap decrease with the decrease of h. The LoF pores caused by weak inter-layer metallurgical bonding are affected by the surface morphology of the previous layer, which is increased as the h increases. The layer rotation can also reduce such LoF pores. On this basis, a quality control chart suitable for actual production is established.
关键词	Additive manufacturing DEM/CFD simulations Multi-layer laser powder bed fusion Surface roughness Pore defects
资助者	Liaoning Revitalization Talents Pro-gram ; CAS Interdisciplinary Innovation Team Project
DOI	10.1016/j.addma.2024.104530
收录类别	SCI
语种	英语
资助项目	Liaoning Revitalization Talents Pro-gram[XLYC1805007] ; CAS Interdisciplinary Innovation Team Project[JCTD-2020-10]
WOS研究方向	Engineering ; Materials Science
WOS类目	Engineering, Manufacturing ; Materials Science, Multidisciplinary
WOS记录号	WOS:001355373200001
出版者	ELSEVIER
引用统计	被引频次：1[WOS] [WOS记录] [WOS相关记录]
文献类型	期刊论文
条目标识符	http://ir.imr.ac.cn/handle/321006/191452
专题	中国科学院金属研究所
通讯作者	An, Xizhong
作者单位	1.Northeastern Univ, Sch Met, Key Lab Ecol Met Multimet Mineral, Minist Educ, Shenyang 110819, Peoples R China 2.Chinese Acad Sci, Inst Met Res, Shichangxu Adv Mat Innovat Ctr, Shenyang 110016, Liaoning, Peoples R China
推荐引用方式 GB/T 7714	Long, Yifu,An, Xizhong,Wang, Ju,et al. Surface roughness and pore evolutions in multi-layer laser powder bed fusion of extra-low interstitial Ti-5Al-2.5Sn powder: A numerical study[J]. ADDITIVE MANUFACTURING,2024,95:21.
APA	Long, Yifu.,An, Xizhong.,Wang, Ju.,Li, Meng.,Wu, Qiong.,...&Zhang, Xing.(2024).Surface roughness and pore evolutions in multi-layer laser powder bed fusion of extra-low interstitial Ti-5Al-2.5Sn powder: A numerical study.ADDITIVE MANUFACTURING,95,21.
MLA	Long, Yifu,et al."Surface roughness and pore evolutions in multi-layer laser powder bed fusion of extra-low interstitial Ti-5Al-2.5Sn powder: A numerical study".ADDITIVE MANUFACTURING 95(2024):21.