Phase-field model of interface migration and powder consolidation in additive manufacturing of metals

M. D. Krivilyov; S. Dj Mesarovic; D. P. Sekulic

doi:10.1007/s10853-016-0311-z

Phase-field model of interface migration and powder consolidation in additive manufacturing of metals

M. D. Krivilyov
, S. Dj Mesarovic
, D. P. Sekulic

Research output: Contribution to journal › Article › peer-review

35 Scopus citations

Abstract

Consolidation phenomena are of fundamental importance for additive manufacturing since the quality of metal parts produced by selective laser melting (SLM) is greatly dependent on residual porosity. The most recent studies use the lattice Boltzmann method (LBM) to analyze conjugated multiphase flow, heat transport, and phase transitions in the molten zone. A phase-field approach suggested in this paper retains all advantages of LBM and provides an alternative tool for theoretical analysis of SLM. In case of consolidation of composite powders where wetting phenomena are crucial at the matrix-inclusion interfaces, the phase-field method is more suitable. In this paper, the problem of metallic powder consolidation is numerically studied and the dynamics of pore and gas bubbles evolution in the molten zone is described. A two-step mechanism of consolidation is proposed which differs from a single-step mechanism typical for additive manufacturing of polymer powders. The consolidation time for different particle orderings is studied and an algorithm for the parameter selection in the widely used viscoplastic model is derived.

Original language	English
Pages (from-to)	4155-4163
Number of pages	9
Journal	Journal of Materials Science
Volume	52
Issue number	8
DOIs	https://doi.org/10.1007/s10853-016-0311-z
State	Published - Apr 1 2017

Bibliographical note

Publisher Copyright:
© 2016, Springer Science+Business Media New York.

Funding

This work has been supported in part through US NSF Grant CBET # 1234581 and US NSF Grant CBET # 1235759. DPS acknowledges support by the 1000 Plan Foreign Expert Professor Talent Program at the Harbin Institute of Technology, Harbin, China. MK acknowledges partial financial support within the Projects No. 2049 of the Ministry of Education and Science, No. 14-29-10282 funded by RFBR and space experiment PERITECTICA funded by the Russian Space Agency and TSNIIMASH.

Funders	Funder number
TSNIIMASH
1000 Plan Foreign Expert Professor Talent Program
Russian Foundation for Basic Research
Russian Space Agency
National Science Foundation Arctic Social Science Program	CBET # 1235759, 1234581
Harbin Institute of Technology, Harbin, China	2049
Spanish Science and Education Ministry	14-29-10282

ASJC Scopus subject areas

Ceramics and Composites
Materials Science (miscellaneous)
General Materials Science
Mechanics of Materials
Mechanical Engineering
Polymers and Plastics

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10.1007/s10853-016-0311-z

Cite this

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abstract = "Consolidation phenomena are of fundamental importance for additive manufacturing since the quality of metal parts produced by selective laser melting (SLM) is greatly dependent on residual porosity. The most recent studies use the lattice Boltzmann method (LBM) to analyze conjugated multiphase flow, heat transport, and phase transitions in the molten zone. A phase-field approach suggested in this paper retains all advantages of LBM and provides an alternative tool for theoretical analysis of SLM. In case of consolidation of composite powders where wetting phenomena are crucial at the matrix-inclusion interfaces, the phase-field method is more suitable. In this paper, the problem of metallic powder consolidation is numerically studied and the dynamics of pore and gas bubbles evolution in the molten zone is described. A two-step mechanism of consolidation is proposed which differs from a single-step mechanism typical for additive manufacturing of polymer powders. The consolidation time for different particle orderings is studied and an algorithm for the parameter selection in the widely used viscoplastic model is derived.",

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Phase-field model of interface migration and powder consolidation in additive manufacturing of metals

Abstract

Bibliographical note

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