A Multiphysics Modeling Approach to Assess the Powder Bed Characteristics of High Strength Steel in Selective Laser Melting

Date

2022

Authors

Rangapuram, M.
Yang, M.
Babalola, S.
Newkirk, J.W.
Bartlett, L.N.
Liou, F.F.
Chandrashekhara, K.

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Abstract

Selective laser melting (SLM) is a type of additive manufacturing technique which uses a powder bed to form complex metal parts in a layer-by-layer process. The density of the powder bed in SLM affects the mechanical properties of the produced part. Good powder packing results in a higher powder bed density which in turn influences the quality of the produced part. In this work, a computational fluid dynamics (CFD) model was developed for the SLM process using Flow 3D software to study the effect of powder bed density on the melt pool characteristics of high strength steel. Discrete element method (DEM) was used to generate powder beds with realistic powder properties. The realistic powder properties of AF9628 were obtained using JMatPro software. The powder beds were irradiated with a moving laser heat source to study the melt pool characteristics. These models were validated with experimental results.

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