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Numerical simulation for electron beam selective melting PBF additive manufacturing of molybdenum

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Abstract

Molybdenum is a newly added material in additive manufacturing material cabinet, and it is under the spotlight owing to its crucial applications. The high-energy electron beam selective melting (EBSM) process is supposed to be a promising technique for molybdenum printing because of its vacuum environment. This paper presents EBSM numerical process simulation for molybdenum on macro- and mesoscale established with exclusive powder material modeling. Experimentally determined, process parameters are implemented in 3D macro- and 2D mesoscale models for a profound process insight. Primarily molybdenum powder material model is established, and a multi-track FEM simulation is performed to predict melt pool configuration, temperature field and phase transformation. Next, powder consolidation mechanism, side surface roughness, porosity, and voids are investigated through a CFD model, where the molybdenum particles are explicitly considered from the EBSM process viewpoint. Results proved the effectiveness of the numerical simulation for detailed EBSM process understanding for molybdenum material.

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Acknowledgements

The principal author would like to extend his gratitude to Prof. Ghulam Hussain and Ghulam Ishaq Khan Institute of Engineering Science & Technology, Topi, Pakistan, for visiting scholar position during pandemic outbreak.

Funding

This work is supported by the funding of the National Key R&D Program of China (2017YFB1103300), State Key Lab of Tribology, Tsinghua University China (SKLT2018B06), and National Natural Science Foundation of China (51975320).

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Authors and Affiliations

  1. State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, People’s Republic of China

    Muhammad Qasim Zafar, Chaochao Wu & Haiyan Zhao

  2. Key Laboratory of Advanced Materials Processing Technology, Ministry of Education, Tsinghua University, Beijing, 100084, People’s Republic of China

    Muhammad Qasim Zafar, Chaochao Wu, Haiyan Zhao, Du Kai & Qianming Gong

  3. School of Material Science & Engineering, Tsinghua University, Beijing, 100084, People’s Republic of China

    Du Kai & Qianming Gong

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  1. Muhammad Qasim Zafar
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  2. Chaochao Wu
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  4. Du Kai
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Contributions

Muhammad Qasim Zafar: Molybdenum material modeling, FEM simulation, and writing/revision/proofreading—original draft. Chaochao Wu: mesoscale simulation and writing. Prof. Haiyan Zhao: supervision, resources, and review. Du Kai: EBSM experiments. Prof. Qianming Gong: experiments and supervision.

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Correspondence to Haiyan Zhao or Qianming Gong.

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Zafar, M.Q., Wu, C., Zhao, H. et al. Numerical simulation for electron beam selective melting PBF additive manufacturing of molybdenum. Int J Adv Manuf Technol 117, 1575–1588 (2021). https://doi.org/10.1007/s00170-021-07671-6

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