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Research Papers

Numerical Simulation of Direct Metal Laser Sintering of Single-Component Powder on Top of Sintered Layers

[+] Author and Article Information
Bin Xiao1

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

Yuwen Zhang2

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

1

Present address: Department of Mechanical Engineering, University of Connecticut, Storrs, CT 06269.

2

Corresponding author.

J. Manuf. Sci. Eng 130(4), 041002 (Jul 08, 2008) (10 pages) doi:10.1115/1.2951948 History: Received June 05, 2006; Revised April 28, 2008; Published July 08, 2008

A three-dimensional model describing melting and resolidification of direct metal laser sintering of loose powders on top of sintered layers with a moving Gaussian laser beam is developed. Natural convection in the liquid pool driven by buoyancy and Marangoni effects is taken into account. A temperature transforming model is employed to model melting and resolidification in the laser sintering process. The continuity, momentum, and energy equations are solved using a finite volume method. The effects of dominant processing parameters including number of the existing sintered layers underneath, laser scanning velocity, and initial porosity on the sintering process are investigated.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

Physical model for DMLS on top of sintered layers

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Figure 2

Comparison of experimental and calculation results for laser fusion of 6063 aluminum sheet

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Figure 3

The temperature distribution at the surface of the powder layer (Δs=0.4, Ub=0.02, ε=0.5, N=5)

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Figure 4

Three-dimensional shape of the HAZ (Δs=0.4, Ub=0.02, ε=0.5): (a) N=1 and (b) N=5

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Figure 5

Dimensionless velocity vector plot (Δs=0.4, Ub=0.02, ε=0.5, N=5): (a) top view, (b) longitudinal view at y=0, and (c) cross-sectional view at x=0

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Figure 6

Dimensionless temperature contour (Δs=0.4, Ub=0.02, ε=0.5, N=5): (a) top view, (b) longitudinal view at y=0 and (c) cross-sectional view at x=0

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Figure 7

Effect of laser intensity and scanning velocity on the sintering process with only one existing sintered layer (ε=0.5, N=1): (a) longitudinal view at y=0 and (b) cross-sectional view at x=0

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Figure 8

Effect of laser intensity and scanning velocity on the sintering process with three existing sintered layers (ε=0.5, N=3): (a) longitudinal view at y=0 and (b) cross-sectional view at x=0

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Figure 9

Effect of laser intensity and scanning velocity on the sintering process with five existing sintered layers (ε=0.5, N=5): (a) longitudinal view at y=0 and (b) cross-sectional view at x=0

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