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Validated Dimensionless Scaling Law for Melt Pool Width in Laser Powder Bed Fusion
Journal of Materials Processing Technology ( IF 6.3 ) Pub Date : 2021-08-04 , DOI: 10.1016/j.jmatprotec.2021.117316
Yangyiwei Yang 1 , Alexander Großmann 2 , Patrick Kühn 1 , Jan Mölleney 2 , Lorenz Kropholler 2 , Christian Mittelstedt 2 , Bai-Xiang Xu 1
Affiliation  

The melting process during laser powder bed fusion (LPBF) is accompanied by complex physical phenomena, which can rarely be scaled with acceptable effort to utilize the melting process in component design to obtain tailored mechanical properties with adequate machine productivity. A constitutive law relating melt pool geometry to the process parameters thereby plays an essential role in practically fostering machine productivity and component quality in LPBF. In this work, we derive an enhanced dimensionless scaling law based on dimensional analysis to characterize the melt pool width, which is also capable in scaling the beam-size-dependent laser attenuation. Measurements from LPBF-produced specimens and 3D phenomenological LPBF finite element simulations are also performed in batch to validate the derived law. The regression analysis presents the correlation 97-98% for the simulated melt pool widths and 70-90% for experimental measured ones, with fabricated minimum strut thickness of 113 μm. After scaling the effective laser power with the calibrated laser attenuation, the proposed scaling law can be extended to be beam-size independent, as demonstrated by the regression of overall experimental measurements and simulation results, performed under different laser beam diameter, to the unified law with correlation 97%. It demonstrates the feasibility of proposed scaling law in melt pool controlled LPBF manufacturing for designing and producing thin-walled components with strut thicknesses in the micrometer range.



中文翻译:

经验证的激光粉末床融合熔池宽度的无量纲缩放定律

激光粉末床熔化 (LPBF) 过程中的熔化过程伴随着复杂的物理现象,很少能通过可接受的努力来缩放这些现象,以在部件设计中利用熔化过程来获得具有足够机器生产率的定制机械性能。因此,将熔池几何形状与工艺参数相关联的本构法则在实际提高 LPBF 中的机器生产率和部件质量方面起着至关重要的作用。在这项工作中,我们基于尺寸分析推导出增强的无量纲缩放定律来表征熔池宽度,这也能够缩放与光束尺寸相关的激光衰减。LPBF 生产的样本的测量和 3D 现象学 LPBF 有限元模拟也分批进行,以验证导出的规律。97——98% 对于模拟熔池宽度和 70——90% 对于实验测量的,制造的最小支柱厚度为 113 μ米。在使用校准的激光衰减缩放有效激光功率后,所提出的缩放定律可以扩展为与光束尺寸无关,如在不同激光束直径下进行的整体实验测量和模拟结果回归到统一定律所证明的有相关性97%. 它证明了在熔池控制的 LPBF 制造中提出的缩放定律的可行性,用于设计和生产支柱厚度在微米范围内的薄壁部件。

更新日期:2021-08-05
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