Physics of humping formation in laser powder bed fusion

•Implementation of ray tracing heat source in the CFD model•Good consistency between simulations and experiments•Humping defects in samples fabricated at high laser power and scanning speed•Discussion on the roles of various force on humping formation Despite of the promising attributes of laser pow...

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Published in:	International journal of heat and mass transfer Vol. 149; p. 119172
Main Authors:	Tang, C., Le, K.Q., Wong, C.H.
Format:	Journal Article
Language:	English
Published:	Oxford Elsevier Ltd 01.03.2020 Elsevier BV
Subjects:	Additive manufacturing Austenitic stainless steels Capillary flow Computational fluid dynamics Computer simulation Contact angle Flow stability Flux density Humping Industrial applications Laser powder bed fusion Lasers Porosity Powder beds Rapid prototyping Ray tracing algorithm Recoil Scanning Shear forces Surface defects Surface morphology Surface roughness Surface stability Surface tension Swelling Laser powder bed fusion Ray tracing algorithm Additive manufacturing Computational fluid dynamics Surface morphology Humping
ISSN:	0017-9310, 1879-2189
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Abstract	•Implementation of ray tracing heat source in the CFD model•Good consistency between simulations and experiments•Humping defects in samples fabricated at high laser power and scanning speed•Discussion on the roles of various force on humping formation Despite of the promising attributes of laser powder bed fusion, part quality such as porosity and surface roughness remains a critical issue for industrial applications. Humping is a surface defect that may greatly deteriorate the mechanical performances of as-built components. However, current understanding of humping formation remains vague and unclear. In this respect, laser powder bed fusion of stainless steel 316 L single tracks was simulated by using computational fluid dynamics. With the same linear energy density, the simulated tracks exhibit irregular humps at high scanning velocities, which is validated against experiments. In addition, flow kinetics was analyzed to elucidate the physical origins of humping formation during printing process. The study reveals the various effects of surface tension, Marangoni shear force, viscous force and recoil pressure on the humping phenomenon in laser powder bed fusion. At relatively high scanning speed, a swelling with large contact angle is formed due to the competition between surface tension and flow inertia. Capillary instability divides the swelling into separated regions, which is responsible for the humping formation during printing process.
AbstractList	•Implementation of ray tracing heat source in the CFD model•Good consistency between simulations and experiments•Humping defects in samples fabricated at high laser power and scanning speed•Discussion on the roles of various force on humping formation Despite of the promising attributes of laser powder bed fusion, part quality such as porosity and surface roughness remains a critical issue for industrial applications. Humping is a surface defect that may greatly deteriorate the mechanical performances of as-built components. However, current understanding of humping formation remains vague and unclear. In this respect, laser powder bed fusion of stainless steel 316 L single tracks was simulated by using computational fluid dynamics. With the same linear energy density, the simulated tracks exhibit irregular humps at high scanning velocities, which is validated against experiments. In addition, flow kinetics was analyzed to elucidate the physical origins of humping formation during printing process. The study reveals the various effects of surface tension, Marangoni shear force, viscous force and recoil pressure on the humping phenomenon in laser powder bed fusion. At relatively high scanning speed, a swelling with large contact angle is formed due to the competition between surface tension and flow inertia. Capillary instability divides the swelling into separated regions, which is responsible for the humping formation during printing process. Despite of the promising attributes of laser powder bed fusion, part quality such as porosity and surface roughness remains a critical issue for industrial applications. Humping is a surface defect that may greatly deteriorate the mechanical performances of as-built components. However, current understanding of humping formation remains vague and unclear. In this respect, laser powder bed fusion of stainless steel 316 L single tracks was simulated by using computational fluid dynamics. With the same linear energy density, the simulated tracks exhibit irregular humps at high scanning velocities, which is validated against experiments. In addition, flow kinetics was analyzed to elucidate the physical origins of humping formation during printing process. The study reveals the various effects of surface tension, Marangoni shear force, viscous force and recoil pressure on the humping phenomenon in laser powder bed fusion. At relatively high scanning speed, a swelling with large contact angle is formed due to the competition between surface tension and flow inertia. Capillary instability divides the swelling into separated regions, which is responsible for the humping formation during printing process.
ArticleNumber	119172
Author	Le, K.Q. Tang, C. Wong, C.H.
Author_xml	– sequence: 1 givenname: C. surname: Tang fullname: Tang, C. email: tangchao@ntu.edu.sg organization: Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore – sequence: 2 givenname: K.Q. surname: Le fullname: Le, K.Q. organization: Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore – sequence: 3 givenname: C.H. surname: Wong fullname: Wong, C.H. email: chwongsgsg@gmail.com organization: Independent Researcher, Singapore
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Keywords	Laser powder bed fusion Ray tracing algorithm Additive manufacturing Computational fluid dynamics Surface morphology Humping
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Snippet	•Implementation of ray tracing heat source in the CFD model•Good consistency between simulations and experiments•Humping defects in samples fabricated at high... Despite of the promising attributes of laser powder bed fusion, part quality such as porosity and surface roughness remains a critical issue for industrial...
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SubjectTerms	Additive manufacturing Austenitic stainless steels Capillary flow Computational fluid dynamics Computer simulation Contact angle Flow stability Flux density Humping Industrial applications Laser powder bed fusion Lasers Porosity Powder beds Rapid prototyping Ray tracing algorithm Recoil Scanning Shear forces Surface defects Surface morphology Surface roughness Surface stability Surface tension Swelling
Title	Physics of humping formation in laser powder bed fusion
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