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Eulerian–Lagrangian Numerical Simulation of Powder Bed Denudation and Spatter Behavior During Powder Bed Fusion Process

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Abstract

Powder bed fusion using a laser beam (PBF-LB) is rapidly developing toward high laser power, high scanning speed, and multiple lasers; however, spatter has become one of the major bottlenecks limiting PBF-LB to form large metal parts. In this paper, the Eulerian–Lagrangian numerical simulation study was carried out for the spatter formation and spatter-protective gas flow coupling behavior. Among them, the Eulerian model considered the effect of particles on the gas-phase flow, and the Lagrangian model took into account the fluid drag force, gravity, buoyancy, non-uniform pressure distribution, additional mass force, and particle–particle collisions. For the effect of metal vapor on spatter and powder bed denudation, it was found that the larger the metal vapor jet speed or jet area, the faster the spatter speed and the larger the width of the powder bed denudation zone; the larger the lateral dimension of the metal vapor action zone (the scanning direction is longitudinal), the larger the number of spatters. For the effect of protective gas flow velocity on spatter movement, it was found that the longitudinal movement distance of spatter was significantly larger for larger protective gas flow velocity, and almost all spatters fell on the powder bed or substrate for smaller protective gas flow velocity. This paper is expected to provide scientific guidance for regulating PBF-LB spatter.

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Acknowledgments

This work was supported by the Basic and Applied Basic Research Project of Guangzhou Basic Research Program (no. 202102020724), the Natural Science Foundation of Guangdong Province (no. 2019A1515012040), and the Fast Support Project (No. 80923010304).

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On behalf of all authors, the corresponding author states that there is no conflict of interest.

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Authors and Affiliations

  1. Institute for Systems Rheology, School of Mechanical and Electrical Engineering, Guangzhou University, Guangzhou, 510006, Guangdong, P.R. China

    Liu Cao, Rui-Fan Meng, Qin-Dan Zhang & Zhen-Zhen Gui

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  1. Liu Cao
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  2. Rui-Fan Meng
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Cao, L., Meng, RF., Zhang, QD. et al. Eulerian–Lagrangian Numerical Simulation of Powder Bed Denudation and Spatter Behavior During Powder Bed Fusion Process. Metall Mater Trans A 54, 2771–2790 (2023). https://doi.org/10.1007/s11661-023-07055-3

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  • DOI: https://doi.org/10.1007/s11661-023-07055-3

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