Extending the hybrid-viscosity-continuum model to predict the melt pool dynamics during powder bed fusion additive manufacturing processes
摘要
To qualify process parameters in powder bed fusion metal additive manufacturing, a high-fidelity thermofluid model is desired to understand the dynamics of the melt pool. Both process, material, and modeling parameters affect the dynamics of the melt pool. Modeling parameters that often depend on material properties, such as viscosity and other physical characteristics of the material, are typically the first to be considered when developing a thermofluid computational fluid dynamics model. Also, during processing, process parameters determine the quality of the final parts. Therefore, this study used a hybrid-viscosity-continuum model to study the melt pool dynamics under varying influences of modeling and process parameters such as the critical solid fractions, viscosity model, dendritic arm spacing, laser power, and scanning speed. The simulation results were compared to experimentally measured melt pool dimensions, and a good agreement was achieved. The model captures the evolution and dynamics of pore formation in the melt pool. The melt pool dimensions were unaffected as the critical solid fractions increased, and the melt track surface morphology height was slightly affected. Under different laser power and scanning speed the melt pool morphology was strongly affected. The results obtained could inform process parameter planning and qualification in the LPBF additive manufacturing processes.