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粉末床熔融增材制造工艺窗口的预测模拟：粉末堆积密度的影响

Predictive Simulation of Process Windows for Powder Bed Fusion Additive Manufacturing: Influence of the Powder Bulk Density.

作者信息

Rausch Alexander M, Küng Vera E, Pobel Christoph, Markl Matthias, Körner Carolin

机构信息

Chair of Materials Science and Engineering for Metals (WTM), Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Martensstr. 5, D-91058 Erlangen, Germany.

Joint Institute of Advanced Materials and Processes (ZMP), Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Dr.-Mack-Str. 81, D-90762 Fürth, Germany.

出版信息

Materials (Basel). 2017 Sep 22;10(10):1117. doi: 10.3390/ma10101117.

DOI:10.3390/ma10101117
PMID:28937633
原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC5666923/
Abstract

The resulting properties of parts fabricated by powder bed fusion additive manufacturing processes are determined by their porosity, local composition, and microstructure. The objective of this work is to examine the influence of the stochastic powder bed on the process window for dense parts by means of numerical simulation. The investigations demonstrate the unique capability of simulating macroscopic domains in the range of millimeters with a mesoscopic approach, which resolves the powder bed and the hydrodynamics of the melt pool. A simulated process window reveals the influence of the stochastic powder layer. The numerical results are verified with an experimental process window for selective electron beam-melted Ti-6Al-4V. Furthermore, the influence of the powder bulk density is investigated numerically. The simulations predict an increase in porosity and surface roughness for samples produced with lower powder bulk densities. Due to its higher probability for unfavorable powder arrangements, the process stability is also decreased. This shrinks the actual parameter range in a process window for producing dense parts.

摘要

通过粉末床熔融增材制造工艺制造的零件的最终性能取决于其孔隙率、局部成分和微观结构。这项工作的目的是通过数值模拟研究随机粉末床对致密零件工艺窗口的影响。研究表明，采用介观方法能够以独特的能力模拟毫米范围内的宏观区域，该方法可解析粉末床和熔池的流体动力学。模拟的工艺窗口揭示了随机粉末层的影响。数值结果通过选择性电子束熔化Ti-6Al-4V的实验工艺窗口进行了验证。此外，还对粉末松装密度的影响进行了数值研究。模拟预测，使用较低粉末松装密度生产的样品孔隙率和表面粗糙度会增加。由于不利粉末排列的可能性更高，工艺稳定性也会降低。这缩小了生产致密零件工艺窗口中的实际参数范围。

https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/463fcb39337f/materials-10-01117-g007.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/438a9b94659a/materials-10-01117-g001.jpg
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https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/bab6d0db917c/materials-10-01117-g004.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/9fa6d8c45f2b/materials-10-01117-g005.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/eb724cf57f7f/materials-10-01117-g006.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/463fcb39337f/materials-10-01117-g007.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/438a9b94659a/materials-10-01117-g001.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/5126f1c22ae0/materials-10-01117-g002.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/38e13281f02c/materials-10-01117-g003.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/bab6d0db917c/materials-10-01117-g004.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/9fa6d8c45f2b/materials-10-01117-g005.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/eb724cf57f7f/materials-10-01117-g006.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/fdc2/5666923/463fcb39337f/materials-10-01117-g007.jpg

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