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Influence of processing parameters on laser penetration depth and melting/re-melting densification during selective laser melting of aluminum alloy

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Abstract

A three-dimensional mesoscopic model, considering the powder-to-solid transition, motion of gas bubbles within molten pool and the effect of surface tension, has been established in order to investigate the evolution rule of pores and re-melting densification mechanism during selective laser melting of AlSi10Mg. The results indicated that re-melting phenomenon of previous fabricated layer induced by laser melting of current powder layer played a crucial role on the increase in densification rate. During the re-melting process, the trapped gas pores in previous layer rose up swiftly and came to the surface consequently, resulting in remarkably elevated densification in previous layer. The influences of laser scan speed on the single-track morphology, types of pores and laser penetration depth have also been studied. It showed that the maximum re-melting depth (31 µm) was attained, and meanwhile, pores left in preceding layer got eliminated completely due to the mass transfer within molten pool, when an appropriate laser scan speed (150 mm/s) was applied. In this case, reasonable laser energy per unit length and irradiation time tended to enhance the laser penetration depth for powder bed and decrease the porosity in as-fabricated layer. A series of experimental study were performed to verify the reliability of the above mesoscopic simulation, including the surface topography of single track and the types of pores. The redistribution of bubbles between the adjacent layers as well as the localized re-melting densification, which were observed from the longitudinal section of samples, was in good agreement with simulation results.

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Acknowledgments

The authors gratefully acknowledge the financial support from the National Natural Science Foundation of China (Nos. 51575267, 51322509), the National Key Research and Development Program “Additive Manufacturing and Laser Manufacturing” (No. 2016YFB1100101), the Top-Notch Young Talents Program of China, the NSFC-DFG Sino-German Research Project (No. GZ 1217), the Outstanding Youth Foundation of Jiangsu Province of China (No. BK20130035), the Program for New Century Excellent Talents in University (No. NCET-13-0854), the Science and Technology Support Program (The Industrial Part), Jiangsu Provincial Department of Science and Technology of China (No. BE2014009-2), the 333 Project (No. BRA2015368), the Aeronautical Science Foundation of China (No. 2015ZE52051), the Shanghai Aerospace Science and Technology Innovation Fund (No. SAST2015053), the Fundamental Research Funds for the Central Universities (Nos. NE2013103, NP2015206, NZ2016108) and the Priority Academic Program Development of Jiangsu Higher Education Institutions.

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Authors and Affiliations

  1. College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Yudao Street 29, Nanjing, 210016, People’s Republic of China

    Guanqun Yu, Dongdong Gu, Donghua Dai, Mujian Xia, Chenglong Ma & Kun Chang

  2. Institute of Additive Manufacturing (3D Printing), Nanjing University of Aeronautics and Astronautics, Yudao Street 29, Nanjing, 210016, People’s Republic of China

    Guanqun Yu, Dongdong Gu, Donghua Dai, Mujian Xia, Chenglong Ma & Kun Chang

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  1. Guanqun Yu
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  2. Dongdong Gu
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  3. Donghua Dai
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Correspondence to Dongdong Gu.

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Yu, G., Gu, D., Dai, D. et al. Influence of processing parameters on laser penetration depth and melting/re-melting densification during selective laser melting of aluminum alloy. Appl. Phys. A 122, 891 (2016). https://doi.org/10.1007/s00339-016-0428-6

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