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TECHNICAL PAPERS

Three-Dimensional Modeling of Selective Laser Sintering of Two-Component Metal Powder Layers

[+] Author and Article Information
Tiebing Chen

Department of Mechanical and Aerospace Engineering, University of Missouri-Columbia, Columbia, MO 65211

Yuwen Zhang1

Department of Mechanical and Aerospace Engineering, University of Missouri-Columbia, Columbia, MO 65211zhangyu@missouri.edu

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng 128(1), 299-306 (Jul 16, 2005) (8 pages) doi:10.1115/1.2122947 History: Received January 20, 2005; Revised July 16, 2005

Laser sintering of a metal powder mixture that contains two kinds of metal powders with significantly different melting points under a moving Gaussian laser beam is investigated numerically. The continuous-wave laser-induced melting accompanied by shrinkage and resolidification of the metal powder layer are modeled using a temperature-transforming model. The liquid flow of the melted low-melting-point metal driven by capillary and gravity forces is also included in the physical model. The numerical results are validated by experimental results, and a detailed parametric study is performed. The effects of the moving heat source intensity, the scanning velocity, and the thickness of the powder layer on the sintering depth, the configuration of the heat affected zone, and the temperature distribution are discussed.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 2

Three-dimensional shape of the HAZ (Δ=0.25, Ub=0.1, Ni=0.0125)

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Figure 3

Temperature distribution at the surface of the powder layer (Δ=0.25, Ub=0.1, Ni=0.0125)

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Figure 11

Effect of the dimensionless moving laser beam intensity on the sintering process (Δ=1.0)

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Figure 12

Effect of the dimensionless scanning velocity on the sintering process (Δ=1.0)

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Figure 10

Effect of the dimensionless scanning velocity on the sintering process (Δ=0.5)

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Figure 9

Effect of the dimensionless moving laser beam intensity on the sintering process (Δ=0.5)

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Figure 8

Effect of the dimensionless scanning velocity on surface temperature distribution (Δ=0.25, Ni=0.0125)

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Figure 7

Effect of the dimensionless scanning velocity on the sintering process (Δ=0.25)

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Figure 6

Effect of the dimensionless laser beam intensity on surface temperature distribution (Δ=0.25, Ub=0.1)

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Figure 5

Effect of the dimensionless moving laser beam intensity on the sintering process (Δ=0.25)

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Figure 4

Comparison of the cross-sectional area obtained by numerical simulation and experiment (Δ=13.47, Ub=0.124, Ni=0.0749)

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