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Temperature thread multiscale finite element simulation of selective laser melting for the evaluation of process

  • Lee, Kang-Hyun (Department of Mechanical & Aerospace Engineering, Seoul National University) ;
  • Yun, Gun Jin (Institute of Advanced Aerospace Technology, Seoul National University)
  • Received : 2020.08.28
  • Accepted : 2020.10.23
  • Published : 2021.01.25
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Abstract

Selective laser melting (SLM), one of the most widely used powder bed fusion (PBF) additive manufacturing (AM) technology, enables the fabrication of customized metallic parts with complex geometry by layer-by-layer fashion. However, SLM inherently poses several problems such as the discontinuities in the molten track and the steep temperature gradient resulting in a high degree of residual stress. To avoid such defects, thisstudy proposes a temperature thread multiscale model of SLM for the evaluation of the process at different scales. In microscale melt pool analysis, the laser beam parameters were evaluated based on the predicted melt pool morphology to check for lack-of-fusion or keyhole defects. The analysis results at microscale were then used to build an equivalent body heat flux model to obtain the residual stress distribution and the part distortions at the macroscale (part level). To identify the source of uneven heat dissipation, a liquid lifetime contour at macroscale was investigated. The predicted distortion was also experimentally validated showing a good agreement with the experimental measurement.

Keywords

Acknowledgement

This work was supported by the Korea Evaluation Institute of Industrial Technology (KEIT) grant funded by the Korea government (MOTIE) (No.20004662, Industrial Technology Innovation Program) and Institute of Engineering Research at Seoul National University. The authors are grateful for their supports.

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