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Heat Source Modeling in Selective Laser Melting

机译：选择性激光熔化中的热源建模

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Selective laser melting (SLM) is an emerging additive manufacturing (AM) technology for metals. Intricate three-dimensional parts can be generated from the powder bed by selectively melting the desired location of the powders. The process is repeated for each layer until the part is built. The necessary heat is provided by a laser. Temperature magnitude and history during SLM directly determine the molten pool dimensions, thermal stress, residual stress, balling effect, and dimensional accuracy. Laser-matter interaction is a crucial physical phenomenon in the SLM process. In this paper, five different heat source models are introduced to predict the three-dimensional temperature field analytically. These models are known as steady state moving point heat source, transient moving point heat source, semi-elliptical moving heat source, double elliptical moving heat source, and uniform moving heat source. The analytical temperature model for all of the heat source models is solved using three-dimensional differential equations of heat conduction with different approaches. The steady state and transient moving heat source are solved using a separation of variables approach. However, the rest of the models are solved by employing Green’s functions. Due to the high temperature in the presence of the laser, the temperature gradient is usually high which has a substantial impact on thermal material properties. Consequently, the temperature field is predicted by considering the temperature sensitivity thermal material properties. Moreover, due to the repeated heating and cooling, the part usually undergoes several melting and solidification cycles, and this physical phenomenon is considered by modifying the heat capacity using latent heat of melting. Furthermore, the multi-layer aspect of the metal AM process is considered by incorporating the temperature history from the previous layer since the interaction of the layers have an impact on heat transfer mechanisms. The proposed temperature field models based on different heat source approaches are validated using experimental measurement of melt pool geometry from independent experimentations. A detailed explanation of the comparison of models is also provided. Moreover, the effect of process parameters on the balling effect is also discussed.
机译：选择性激光熔化（SLM）是一种新兴的金属增材制造（AM）技术。通过选择性地熔化粉末的所需位置，可以从粉末床生成复杂的三维零件。对每一层重复此过程，直到建立零件为止。必要的热量由激光提供。 SLM期间的温度大小和历史直接决定了熔池的尺寸，热应力，残余应力，滚珠效应和尺寸精度。激光物质相互作用是SLM过程中至关重要的物理现象。在本文中，介绍了五个不同的热源模型以分析性地预测三维温度场。这些模型被称为稳态移动点热源，瞬态移动点热源，半椭圆形移动热源，双椭圆形移动热源和均匀移动热源。使用热传导的三维微分方程，采用不同方法求解所有热源模型的解析温度模型。使用变量分离方法求解稳态和瞬态移动热源。但是，其余模型都可以通过采用Green的功能来解决。由于激光存在下的高温，温度梯度通常很高，这对热材料性能有很大影响。因此，通过考虑温度敏感性热材料特性来预测温度场。此外，由于反复进行加热和冷却，部件通常经历几次熔化和固化循环，并且通过使用熔化潜热来改变热容来考虑该物理现象。此外，由于层之间的相互作用会影响传热机理，因此通过合并前一层的温度历史来考虑金属增材制造工艺的多层方面。提出的基于不同热源方法的温度场模型通过独立实验的熔池几何形状实验测量得到验证。还提供了模型比较的详细说明。此外，还讨论了工艺参数对滚珠效果的影响。

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