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<p>The selective laser melting (SLM) process has gained attention in the manufacturing industry due to its capability for producing products with complex shapes through a layer-by-layer addition. Selecting process parameters influences the as-built quality. Among these, the layer thickness and energy input are key parameters impacting the deposited track formation, shrinkage, and defects. This study implemented multi-physics simulation to examine deposited track formation with varying layer thicknesses (L<sub>t</sub>) and linear energy density (LED) and investigate the process parameters impact on surface sinkage induced shrinkage of deposited track in the SLM process of Ti-6Al-4&#xa0;V alloy. The results revealed that layer thickness significantly impacts temperature distribution, molten pool morphology, and surface sinkage of deposited track. With higher layer thicknesses the temperature distribution was transformed from V-shaped to U-shaped due to more uniform heat distribution. LED adjustments play an essential role in both formation and surface sinkage of deposited track. Lower LED at decreased layer thicknesses promotes uniform deposited tracks but can cause humping effect, while higher LED increased penetration depth at higher layer thickness but potential for keyholing and surface sinkage. These findings are expected to provide optimization of Ti-6Al-4&#xa0;V production.</p>

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Formation and shrinkage of deposited track with varying powder layer thicknesses in selective laser melting process: multi-physics simulation

  • 期刊论文

  • 发表日期：

    2025年8月18日

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  • Patiparn Ninpetch,
  • Pruet Kowitwarangkul,
  • Prasert Chalermkarnnon,
  • Kavin Karunratanakul,
  • Kornrawee Munpakdee,
  • Phadungsak Rattanadecho

摘要

The selective laser melting (SLM) process has gained attention in the manufacturing industry due to its capability for producing products with complex shapes through a layer-by-layer addition. Selecting process parameters influences the as-built quality. Among these, the layer thickness and energy input are key parameters impacting the deposited track formation, shrinkage, and defects. This study implemented multi-physics simulation to examine deposited track formation with varying layer thicknesses (Lt) and linear energy density (LED) and investigate the process parameters impact on surface sinkage induced shrinkage of deposited track in the SLM process of Ti-6Al-4 V alloy. The results revealed that layer thickness significantly impacts temperature distribution, molten pool morphology, and surface sinkage of deposited track. With higher layer thicknesses the temperature distribution was transformed from V-shaped to U-shaped due to more uniform heat distribution. LED adjustments play an essential role in both formation and surface sinkage of deposited track. Lower LED at decreased layer thicknesses promotes uniform deposited tracks but can cause humping effect, while higher LED increased penetration depth at higher layer thickness but potential for keyholing and surface sinkage. These findings are expected to provide optimization of Ti-6Al-4 V production.