Understanding the thermo-fluid-microstructural impact of beam shaping in Laser Powder Bed Fusion using high-fidelity multiphysics simulation

Bayat M, Zinovieva O, Zinoviev A, Rothfelder R, Schwarzkopf K, Schmidt M, Hattel JH (2024)


Publication Type: Conference contribution

Publication year: 2024

Journal

Publisher: Elsevier B.V.

Book Volume: 124

Pages Range: 358-361

Conference Proceedings Title: Procedia CIRP

Event location: Fürth DE

DOI: 10.1016/j.procir.2024.08.133

Abstract

Beam shaping of lasers is a topic that has received relatively less attention in the context of metal additive manufacturing (MAM) processes. This technique allows for modulation or spatial alternation of the intensity profile of the laser. As the bulk of the work within MAM primarily revolves around Gaussian beam profiles, the precise impact and potential of other beam shapes is still an unanswered question. In this work a multiphysics numerical model of the laser powder bed fusion (LPBF) process of Ti6Al4V without powder is developed and the model can predict thermofluid-microstructural conditions. The model predictions are compared with experimental data from single-Track specimens, and the comparison shows a very good agreement. It is shown that the ring spot beam profile (RSBP) results in substantially wider melt pools as compared to the ones forming using the Gaussian beam profile (GBP). The microstructural predictions show that for GBP the grains converge to the center line of the melt pool, while for ring beam profile (RBP), the grains tend to converge to a single point. Finally, the impact of different ring radii for RBP is studied and the results show that at larger ring radii, a noticeable bulge of liquid metal forms right beneath the laser beam.

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How to cite

APA:

Bayat, M., Zinovieva, O., Zinoviev, A., Rothfelder, R., Schwarzkopf, K., Schmidt, M., & Hattel, J.H. (2024). Understanding the thermo-fluid-microstructural impact of beam shaping in Laser Powder Bed Fusion using high-fidelity multiphysics simulation. In Michael Schmidt, C.B. Arnold, K. Wudy (Eds.), Procedia CIRP (pp. 358-361). Fürth, DE: Elsevier B.V..

MLA:

Bayat, Mohamad, et al. "Understanding the thermo-fluid-microstructural impact of beam shaping in Laser Powder Bed Fusion using high-fidelity multiphysics simulation." Proceedings of the 13th CIRP Conference on Photonic Technologies, LANE 2024, Fürth Ed. Michael Schmidt, C.B. Arnold, K. Wudy, Elsevier B.V., 2024. 358-361.

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