An official website of the United States government
Abstract Challenge 3 of the 2022 NIST additive manufacturing benchmark (AM Bench) experiments asked modelers to submit predictions for solid cooling rate, liquid cooling rate, time above melt, and melt pool geometry for single and multiple track laser powder bed fusion process using moving lasers. An in-house developedAdditiveManufacturingComputationalFluidDynamics code (AM-CFD) combined with a cylindrical heat source is implemented to accurately predict these experiments. Heuristic heat source calibration is proposed relating volumetric energy density (ψ) based on experiments available in the literature. The parameters of the heat source of the computational model are initially calibrated based on a Higher Order Proper Generalized Decomposition- (HOPGD) based surrogate model. The prediction using the calibrated heat source agrees quantitatively with NIST measurements for different process conditions (laser spot diameter, laser power, and scan speed). A scaling law based on keyhole formation is also utilized in calibrating the parameters of the cylindrical heat source and predicting the challenge experiments. In addition, an improvement on the heat source model is proposed to relate the Volumetric Energy Density (VEDσ) to the melt pool aspect ratio. The model shows further improvement in the prediction of the experimental measurements for the melt pool, including cases at higher VEDσ. Overall, it is concluded that the appropriate selection of laser heat source parameterization scheme along with the heat source model is crucial in the accurate prediction of melt pool geometry and thermal measurements while bypassing the expensive computational simulations that consider increased physics equations.
more »
« less
Effects of nanoparticles on laser sintering of metal and ceramic powders
Abstract Continuous wave (CW) laser was used to melt micrometer-sized powders mixed with nanoparticles (NPs) such as titanium NPs. Nanoliquids have been known as medium of excellent heat transfer so that commercial nanoliquids are available for more efficient cooling engines and drill bits for oil wells. Nanoliquids may form during the laser melting or sintering of powders that are mixed with NPs of higher melting point than that of powders. During the melting period, NPs may stay in solid phase while the powders become liquid. This powder-transformed to liquid may be viewed as a nanoliquid with solid-state NPs. We discuss the laser melting of powders such as SmCo5with titanium NPs including their hardness. Graphical abstract
more »
« less
- Award ID(s):
- 2122128
- PAR ID:
- 10635446
- Publisher / Repository:
- Cambridge University Press (CUP)
- Date Published:
- Journal Name:
- MRS Advances
- Volume:
- 10
- Issue:
- 16
- ISSN:
- 2731-5894
- Format(s):
- Medium: X Size: p. 1901-1904
- Size(s):
- p. 1901-1904
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Abstract Micro- and nanoporous materials have gathered attention from the scientific community due to their size dependent properties, including but not limited to high specific surface area, surface diffusivity, bulk diffusivity and permeability, catalytic activity, and distinct optical properties. In this work, spherical nanoporous copper (np-Cu) powders, due to their nanosized porosity and low Cu2O content, show hemispherical total reflectance of 20% which is significantly lower than its bulk counterpart value for solid or molten copper of approximately 97% at wavelengths of most commercial Laser Powder Bed Fusion (L-PBF) commercial machines. The low-reflectance of np-Cu powders has the potential to be used in L-PBF to improve laser absorption, volumetric energy efficiency, and throughput of this additive manufacturing process. In fact, a prepared mixture of solid Cu powders containing only 5 wt.% of np-Cu powders reflects 34.8 % less than pure copper powders as shown in this paper. Np-Cu powders are fabricated via chemical dealloying of gas atomized CuAl alloy in a robust and scalable approach, and then mixed with pure copper powders to prepare hybrid feedstocks. Under this framework, the crucial role of deglomeration strategies to achieve homogeneity and flowability of np-Cu/Cu hybrid mixtures are evaluated via particle imaging to determine agglomerate size and composition with an eye at obtaining a high-quality print in L-PBF. In np-Cu powders fabrication, washing them in low-surface tension fluids upholds the highest degree of deglomeration in their fabrication process, and for hybrid feedstocks preparation, pre-mixing Cu and CuAl prior to dealloying yields the best homogeneity results with smallest size of agglomerates and good flowability.more » « less
-
Abstract This paper examined the effect of Si addition on the cracking resistance of Inconel 939 alloy after laser additive manufacturing (AM) process. With the help of CALculation of PHAse Diagrams (CALPHAD) software Thermo-Calc, the amounts of specific elements (C, B, and Zr) in liquid phase during solidification, cracking susceptibility coefficients (CSC) and cracking criterion based on$$\left| {{\text{d}}T/{\text{d}}f_{{\text{s}}}^{1/2} } \right|$$ values (T: solidification temperature,fs: mass fraction of solid during solidification) were evaluated as the indicators for composition optimization. It was found that CSC together with$$\left| {{\text{d}}T/{\text{d}}f_{{\text{s}}}^{1/2} } \right|$$ values provided a better prediction for cracking resistance. Graphical abstractmore » « less
-
Abstract Thermoelectric generators convert heat energy to electricity and can be used for waste heat recovery, enabling sustainable development. Selective Laser Melting (SLM) based additive manufacturing process is a scalable and flexible method that has shown promising results in manufacturing high zT Bi2Te3 material and is possible to be extended to other material classes such as Mg2Si. The physical phenomena of melting and solidification were investigated for SLM-based manufacturing of thermoelectric (Mg2Si) powders through comprehensive numerical models developed in MATLAB. In this study, Computational Fluid Dynamics (CFD)-based techniques were employed to solve conservation equations, enabling a detailed understanding of temperature evolution within the molten pool. This approach was critical for optimizing processing parameters in our investigation, which were also used for printing the Mg2Si powders using SLM. Additionally, a phase field-based model was developed to simulate the directional solidification of the Mg2Si in MATLAB. Microstructural parameters were studied to correlate the effects of processing parameters to the microstructure of Mg2Si.more » « less
-
Abstract H2O transforms to two forms of superionic (SI) ice at high pressures and temperatures, which contain highly mobile protons within a solid oxygen sublattice. Yet the stability field of both phases remains debated. Here, we present the results of an ultrafast X-ray heating study utilizing MHz pulse trains produced by the European X-ray Free Electron Laser to create high temperature states of H2O, which were probed using X-ray diffraction during dynamic cooling. We confirm an isostructural transition during heating in the 26-69 GPa range, consistent with the formation of SI-bcc. In contrast to prior work, SI-fcc was observed exclusively above ~50 GPa, despite evidence of melting at lower pressures. The absence of SI-fcc in lower pressure runs is attributed to short heating timescales and the pressure-temperature path induced by the pump-probe heating scheme in which H2O was heated above its melting temperature before the observation of quenched crystalline states, based on the earlier theoretical prediction that SI-bcc nucleates more readily from the fluid than SI-fcc. Our results may have implications for the stability of SI phases in ice-rich planets, for example during dynamic freezing, where the preferential crystallization of SI-bcc may result in distinct physical properties across mantle ice layers.more » « less
