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<p>Powder bed fusion (PBF) processes are susceptible to spatters, which has the potential to contaminate the powder bed and compromise the quality of printing products. To address this issue, commercial PBF machines utilize an inert gas flow field within the printing chamber to transport spatters outside the powder bed. However, tracking the trajectories of small spatters within the chamber is challenging, prompting the widespread use of numerical simulations as an effective research tool. Different from existing modeling approaches, we employ a three-dimensional coupled Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) multiphysics model, partially resolved using Large Eddy Simulations (LES). The model considers the volume fraction in fluid equations to capture the impact of spatters on the flow field, and resolves large-scale vortices to capture the impact of flow field on the particle transport behavior. Results reveal that the motion of spatters disrupts the gas flow on the bottom, leading to phenomena similar to ‘shaking’ and ‘cutoff’. In order to create a larger effective gas flow region and maintain a relatively stable bottom gas flow, we proposed an opposite-side gas flow inlet design. This novel design scheme enhances the gas-spatter interaction region and minimizes disturbances caused by particles on the bottom gas flow. Simulation results demonstrate that this system configuration achieves a significant improvement in spatter removal efficiency to 92.3% without requiring an increase in the inlet velocity.</p>

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CFD-DEM multiphysics modeling of spatter transport for novel design of gas flow system in powder bed fusion

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Xuanting Liu,
  • Zekun Wang,
  • Jie Zhang,
  • Kai Yang,
  • Moubin Liu

摘要

Powder bed fusion (PBF) processes are susceptible to spatters, which has the potential to contaminate the powder bed and compromise the quality of printing products. To address this issue, commercial PBF machines utilize an inert gas flow field within the printing chamber to transport spatters outside the powder bed. However, tracking the trajectories of small spatters within the chamber is challenging, prompting the widespread use of numerical simulations as an effective research tool. Different from existing modeling approaches, we employ a three-dimensional coupled Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) multiphysics model, partially resolved using Large Eddy Simulations (LES). The model considers the volume fraction in fluid equations to capture the impact of spatters on the flow field, and resolves large-scale vortices to capture the impact of flow field on the particle transport behavior. Results reveal that the motion of spatters disrupts the gas flow on the bottom, leading to phenomena similar to ‘shaking’ and ‘cutoff’. In order to create a larger effective gas flow region and maintain a relatively stable bottom gas flow, we proposed an opposite-side gas flow inlet design. This novel design scheme enhances the gas-spatter interaction region and minimizes disturbances caused by particles on the bottom gas flow. Simulation results demonstrate that this system configuration achieves a significant improvement in spatter removal efficiency to 92.3% without requiring an increase in the inlet velocity.