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<p>In the process of selective laser melting (SLM) for precision manufacturing, increasing the powder layer thickness can directly improve the additive manufacturing rate. But the sources of defects in large powder layer thickness are complex and numerous, especially uneven fusion and pores. For 90&#xa0;µm large powder thickness SLM, it is investigated that for the corrected surface energy density, the effect of line energy density and field width on the top interface morphology and interlayer interface pores. For SLM with a large layer thickness of 90&#xa0;µm, this study investigates the effect of corrected surface energy density on melt morphology in SLM using numerical simulations, especially the effect of line energy density and field width on the top interface morphology and interlayer interface pores. It investigates the variations of melt morphology at different interfaces, as well as the correlation between the top interface (first interface) morphology and the interlayer interface (third interface) pores. The results show that at a line energy density of 0.30 (+ 0.05) J/mm and a field width of 0.125 (+ 0.015) mm, the melt at the top interface flows backward, the melt at the interlayer interface flows backward, and the melt flow direction at the top interface is the same as that at the interlayer interface so that there is consistency in the melt flow. The melt at the interlayer interface is sufficiently fused, and there are fewer pores at the boundaries of the top and bottom melt channels; the melt at the top interface is sufficiently fused, and there are fewer pores at the boundaries of the neighboring melt channels. Based on the multi-interface numerical model, it can help to reveal the evolution of interface morphology and interface porosity and predict the interlayer interface porosity based on the interlayer interface melt morphology.</p>

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Numerical modelling of multi-interface melt morphology for Ti-based composites in 90-µm-thickness selective laser melting

  • 期刊论文

  • 发表日期：

    2025年9月22日

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  • An Zhang,
  • Deqiao Xie,
  • Hao Li,
  • Zhidong Liu,
  • Zongjun Tian,
  • Lida Shen

摘要

In the process of selective laser melting (SLM) for precision manufacturing, increasing the powder layer thickness can directly improve the additive manufacturing rate. But the sources of defects in large powder layer thickness are complex and numerous, especially uneven fusion and pores. For 90 µm large powder thickness SLM, it is investigated that for the corrected surface energy density, the effect of line energy density and field width on the top interface morphology and interlayer interface pores. For SLM with a large layer thickness of 90 µm, this study investigates the effect of corrected surface energy density on melt morphology in SLM using numerical simulations, especially the effect of line energy density and field width on the top interface morphology and interlayer interface pores. It investigates the variations of melt morphology at different interfaces, as well as the correlation between the top interface (first interface) morphology and the interlayer interface (third interface) pores. The results show that at a line energy density of 0.30 (+ 0.05) J/mm and a field width of 0.125 (+ 0.015) mm, the melt at the top interface flows backward, the melt at the interlayer interface flows backward, and the melt flow direction at the top interface is the same as that at the interlayer interface so that there is consistency in the melt flow. The melt at the interlayer interface is sufficiently fused, and there are fewer pores at the boundaries of the top and bottom melt channels; the melt at the top interface is sufficiently fused, and there are fewer pores at the boundaries of the neighboring melt channels. Based on the multi-interface numerical model, it can help to reveal the evolution of interface morphology and interface porosity and predict the interlayer interface porosity based on the interlayer interface melt morphology.