Saad A. Khairallah

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones

Abstract This study demonstrates the significant effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel. A three-dimensional high fidelity powder-scale model reveals how the strong dynamical melt flow generates pore defects, material spattering (sparking), and denudation zones. The melt track is divided into three sections: a topological depression, a transition and a tail region, each being the location of specific physical effects. The inclusion of laser ray-tracing energy deposition in the powder-scale model improves over traditional volumetric energy deposition. It enables partial particle melting, which impacts pore defects in the denudation zone. Different pore formation mechanisms are observed at the edge of a scan track, at the melt pool bottom (during collapse of the pool depression), and at the end of the melt track (during laser power ramp down). Remedies to these undesirable pores are discussed. The results are validated against the experiments and the sensitivity to laser absorptivity is discussed.

Calculation of laser absorption by metal powders in additive manufacturing

We have calculated the absorption of laser light by a powder of metal spheres, typical of the powder employed in laser powder-bed fusion additive manufacturing. Using ray-trace simulations, we show that the absorption is significantly larger than its value for normal incidence on a flat surface, due to multiple scattering. We investigate the dependence of absorption on powder content (material, size distribution, and geometry) and on beam size.

Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas flow. The physics of droplet ejection under strong evaporative flow is described using simulations of the laser powder bed interactions to elucidate the experimental results. Hydrodynamic drag analysis is used to augment the single phase flow model and explain the entrainment phenomenon for 316 L stainless steel and Ti-6Al-4V powder layers. The relevance of vapor driven entrainment of metal micro-particles to similar fluid dynamic studies in other fields of science will be discussed.

Simulation Of The Main Physical Processes In Remote Laser Penetration With Large Laser Spot Size

A 3D model is developed to simulate remote laser penetration of a 1mm Aluminum metal sheet with large laser spot size (∼ 3x3cm2), using the ALE3D multi-physics code. The model deals with the laser-induced melting of the plate and the mechanical interaction between the solid and the melted part through plate elastic-plastic response. The effect of plate oscillations and other forces on plate rupture, the droplet formation mechanism and the influence of gravity and high laser power in further breaking the single melt droplet into many more fragments are analyzed. In the limit of low laser power, the numerical results match the available experiments. The numerical approach couples mechanical and thermal diffusion to hydrodynamics melt flow and accounts for temperature dependent material properties, surface tension, gravity and vapor recoil pressure.

Probing melt pool dynamics and particle ejection using high speed optical diagnostics

We present experimental results and modeling of melt pool dynamics and particle ejection associated with selective laser melting. High speed optical diagnostics are used to probe morphological changes for SS316L. Data is compared to simulations.

Modeling of Powder Absorption in Additive Manufacturing

We have investigated optical absorption by a powder of metal spheres, via ray-trace calculations. The absorptivity significantly exceeds that for normal incidence, because of multiple scattering. The effect of beam size is also discussed.

Full length articleLaser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones

Abstract This study demonstrates the significant effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel. A three-dimensional high fidelity powder-scale model reveals how the strong dynamical melt flow generates pore defects, material spattering (sparking), and denudation zones. The melt track is divided into three sections: a topological depression, a transition and a tail region, each being the location of specific physical effects. The inclusion of laser ray-tracing energy deposition in the powder-scale model improves over traditional volumetric energy deposition. It enables partial particle melting, which impacts pore defects in the denudation zone. Different pore formation mechanisms are observed at the edge of a scan track, at the melt pool bottom (during collapse of the pool depression), and at the end of the melt track (during laser power ramp down). Remedies to these undesirable pores are discussed. The results are validated against the experiments and the sensitivity to laser absorptivity is discussed.

Laser powder-bed fusion additive manufacturing: Effects of main physical processes on dynamical melt flow and pore formation from mesoscopic powder simulation

Abstract This study demonstrates the significant effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel. A three-dimensional high fidelity powder-scale model reveals how the strong dynamical melt flow generates pore defects, material spattering (sparking), and denudation zones. The melt track is divided into three sections: a topological depression, a transition and a tail region, each being the location of specific physical effects. The inclusion of laser ray-tracing energy deposition in the powder-scale model improves over traditional volumetric energy deposition. It enables partial particle melting, which impacts pore defects in the denudation zone. Different pore formation mechanisms are observed at the edge of a scan track, at the melt pool bottom (during collapse of the pool depression), and at the end of the melt track (during laser power ramp down). Remedies to these undesirable pores are discussed. The results are validated against the experiments and the sensitivity to laser absorptivity is discussed.