Finite Element Simulation of Selective Laser Melting process considering Optical Penetration Depth of laser in powder bed

A three dimensional finite element model (FEM) is introduced in this work in order to simulate the melt pool size during the Selective Laser Melting (SLM) process. The model adopts the Optical Penetration Depth (OPD) of laser beam into the powder bed and its dependency on the powder size in definiti...

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Published inMaterials & design Vol. 89; pp. 255 - 263
Main Authors Foroozmehr, Ali, Badrossamay, Mohsen, Foroozmehr, Ehsan, Golabi, Sa’id
Format Journal Article
LanguageEnglish
Published Elsevier Ltd 05.01.2016
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ISSN0264-1275
1873-4197
DOI10.1016/j.matdes.2015.10.002

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Summary:A three dimensional finite element model (FEM) is introduced in this work in order to simulate the melt pool size during the Selective Laser Melting (SLM) process. The model adopts the Optical Penetration Depth (OPD) of laser beam into the powder bed and its dependency on the powder size in definition of the heat source. The model is used to simulate laser melting of a single layer of stainless steel 316L on a thick powder bed. The results of the model for the melt pool depth are validated with the experimental results. The model is then used to predict the effect of different scanning speeds on the melt pool depth, width, and length. The results showed that the melt pool size varies from the beginning of a track to its end and from the first track to the next. The melt pool size, however, reaches a stable condition after a few tracks. This concept was used to simplify the process modeling in which reduces the computational costs. [Display omitted] •The developed Finite Element model is able to predict the melt pool size accurately in the SLM process.•The rate of change in the width of the melt pool by altering the speed is not the same as that of the depth.•The melt pool dimensions reached a steady condition after the third track.•The melt pool depth of each track stayed almost constant after about 2mm from the beginning of the track.
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ISSN:0264-1275
1873-4197
DOI:10.1016/j.matdes.2015.10.002