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A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion

A. M. Philo, S. Mehraban, M. Holmes, S. Sillars, C. J. Sutcliffe, Johann Sienz Orcid Logo, Steve Brown, Nicholas Lavery Orcid Logo

International Journal of Advanced Manufacturing Technology, Volume: 101, Issue: 1-4, Pages: 697 - 714

Swansea University Authors: Johann Sienz Orcid Logo, Steve Brown, Nicholas Lavery Orcid Logo

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DOI (Published version): 10.1007/s00170-018-2770-7

Abstract

Laser powder bed fusion (L-PBF) is a complex process involving a range of multi-scale and multi-physical phenomena. There has been much research involved in creating numerical models of this process using both high and low fidelity modelling approaches where various approximations are made. Generall...

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Published in: International Journal of Advanced Manufacturing Technology
ISSN: 0268-3768 1433-3015
Published: 2019
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URI: https://cronfa.swan.ac.uk/Record/cronfa45563
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spelling 2021-01-15T10:24:49.6557421 v2 45563 2018-11-09 A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion 17bf1dd287bff2cb01b53d98ceb28a31 0000-0003-3136-5718 Johann Sienz Johann Sienz true false 07a865adc76376646bc6c03a69ce35a9 Steve Brown Steve Brown true false 9f102ff59824fd4f7ce3d40144304395 0000-0003-0953-5936 Nicholas Lavery Nicholas Lavery true false 2018-11-09 FGSEN Laser powder bed fusion (L-PBF) is a complex process involving a range of multi-scale and multi-physical phenomena. There has been much research involved in creating numerical models of this process using both high and low fidelity modelling approaches where various approximations are made. Generally, to model single lines within the process to predict melt pool geometry and mode, high fidelity computationally intensive models are used which, for industrial purposes, may not be suitable. The model proposed in this work uses a pragmatic continuum level methodology with an ablation limiting approach at the mesoscale coupled with measured thermophysical properties. This model is compared with single line experiments over a range of input parameters using a modulated yttrium fibre laser with varying power and line speeds for a fixed powder layer thickness. A good trend is found between the predicted and measured width and depth of the tracks for 316L stainless steel where the transition into keyhole mode welds was predicted within 13% of experiments. The work presented highlights that pragmatic reduced physics-based modelling can accurately capture weld geometry which could be applied to more practical based uses in the L-PBF process. Journal Article International Journal of Advanced Manufacturing Technology 101 1-4 697 714 0268-3768 1433-3015 1 3 2019 2019-03-01 10.1007/s00170-018-2770-7 http://dx.doi.org/10.1007/s00170-018-2770-7 COLLEGE NANME Science and Engineering - Faculty COLLEGE CODE FGSEN Swansea University 2021-01-15T10:24:49.6557421 2018-11-09T08:55:44.5893859 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised A. M. Philo 1 S. Mehraban 2 M. Holmes 3 S. Sillars 4 C. J. Sutcliffe 5 Johann Sienz 0000-0003-3136-5718 6 Steve Brown 7 Nicholas Lavery 0000-0003-0953-5936 8 0045563-09112018090038.pdf philo2018.pdf 2018-11-09T09:00:38.1330000 Output 5023249 application/pdf Version of Record true 2018-11-09T00:00:00.0000000 This article is distributed under the terms of the Creative Commons Attribution 4.0 International License . true eng http://creativecommons.org/licenses/by/4.0/
title A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion
spellingShingle A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion
Johann Sienz
Steve Brown
Nicholas Lavery
title_short A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion
title_full A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion
title_fullStr A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion
title_full_unstemmed A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion
title_sort A pragmatic continuum level model for the prediction of the onset of keyholing in laser powder bed fusion
author_id_str_mv 17bf1dd287bff2cb01b53d98ceb28a31
07a865adc76376646bc6c03a69ce35a9
9f102ff59824fd4f7ce3d40144304395
author_id_fullname_str_mv 17bf1dd287bff2cb01b53d98ceb28a31_***_Johann Sienz
07a865adc76376646bc6c03a69ce35a9_***_Steve Brown
9f102ff59824fd4f7ce3d40144304395_***_Nicholas Lavery
author Johann Sienz
Steve Brown
Nicholas Lavery
author2 A. M. Philo
S. Mehraban
M. Holmes
S. Sillars
C. J. Sutcliffe
Johann Sienz
Steve Brown
Nicholas Lavery
format Journal article
container_title International Journal of Advanced Manufacturing Technology
container_volume 101
container_issue 1-4
container_start_page 697
publishDate 2019
institution Swansea University
issn 0268-3768
1433-3015
doi_str_mv 10.1007/s00170-018-2770-7
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
url http://dx.doi.org/10.1007/s00170-018-2770-7
document_store_str 1
active_str 0
description Laser powder bed fusion (L-PBF) is a complex process involving a range of multi-scale and multi-physical phenomena. There has been much research involved in creating numerical models of this process using both high and low fidelity modelling approaches where various approximations are made. Generally, to model single lines within the process to predict melt pool geometry and mode, high fidelity computationally intensive models are used which, for industrial purposes, may not be suitable. The model proposed in this work uses a pragmatic continuum level methodology with an ablation limiting approach at the mesoscale coupled with measured thermophysical properties. This model is compared with single line experiments over a range of input parameters using a modulated yttrium fibre laser with varying power and line speeds for a fixed powder layer thickness. A good trend is found between the predicted and measured width and depth of the tracks for 316L stainless steel where the transition into keyhole mode welds was predicted within 13% of experiments. The work presented highlights that pragmatic reduced physics-based modelling can accurately capture weld geometry which could be applied to more practical based uses in the L-PBF process.
published_date 2019-03-01T03:57:24Z
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score 11.012924

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