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Temporal evolution of temperature gradient and solidification rate in laser powder bed fusion additive manufacturing

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Abstract

Despite all advances in metal additive manufacturing processes, there is limited knowledge about the physical phenomena that take place in the molten pool of powder fusion processes. In particular, further research has to be done to find out how different process parameters affect the melt pool geometry and solidification microstructure. A fast moving heat source and a small melt pool size make it difficult to analyze the physical phenomena in the melt pool experimentally. In this work, a numerical model based on Discrete Element Method was used to simulate the powder distribution and packing. Then, a thermo-fluid model was employed to simulate the molten pool geometry and dynamics. A theoretical study of temperature gradient and solidification rate changes throughout the molten pool lifetime during laser powder bed fusion of Inconel 718 alloy was performed. Our simulations show that the temperature gradient decreases by 25–75% then increases by 1–15% as the material solidifies. The temperature gradient increase is driven by the material’s latent heat. The processing parameters show a minor influence on the solidification parameters just after melting with solidification rates between 0.1 – 0.2 m/s and temperature gradients between 5–10 million K/m. As the solidification proceeds, the effects of the processing parameters become more apparent with final solidification rates around 0.07 – 1.5 m/s and temperature gradients around 1–10 million K/m. The findings of this research help to better understand the thermal behavior of the molten pool, which is critical for controlling the solidification conditions as well as the resultant microstructure and properties.

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The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Funding

This work was partially funded by NASA through Grant Number 80NSSC20K0736 and supported by California State University, Los Angeles.

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  1. Department of Mechanical Engineering, California State University Los Angeles, Los Angeles, CA, 91030, USA

    Jonathan Yoshioka & Mohsen Eshraghi

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  1. Jonathan Yoshioka
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Contributions

All authors contributed to the study conception and design. Data collection, analysis, and first draft preparation were performed by Jonathan Yoshioka. Supervision, review, and editing were performed by Mohsen Eshraghi. All authors read and approved the final manuscript.

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Correspondence to Mohsen Eshraghi.

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Yoshioka, J., Eshraghi, M. Temporal evolution of temperature gradient and solidification rate in laser powder bed fusion additive manufacturing. Heat Mass Transfer 59, 1155–1166 (2023). https://doi.org/10.1007/s00231-022-03318-8

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