In this work,the evolution of melt pool under single-point and single-line printing in the laser engineered net shaping(LENS)process is analyzed.Firstly,the basic structure of the melt pool model of the LENS process i...In this work,the evolution of melt pool under single-point and single-line printing in the laser engineered net shaping(LENS)process is analyzed.Firstly,the basic structure of the melt pool model of the LENS process is established and the necessary assumptions are made.Then,the establishment process of the multi-physical field model of the melt pool is introduced in detail.It is concluded that the simulation model results are highly consistent with the online measurement experiment results in terms of melt pool profile,space temperature gradient,and time temperature gradient.Meanwhile,some parameters,such as the 3D morphology and surface fluid field of the melt pool,which are not obtained in the online measurement experiment,are analyzed.Finally,the influence of changing the scanning speed on the profile,peak temperature,and temperature gradient of the single-line melt pool is also analyzed,and the following conclusions are obtained:With the increase in scanning speed,the profile of the melt pool gradually becomes slender;The relationship between peak temperature and scanning speed is approximately linear in a certain speed range;The space temperature gradient at the tail of the melt pool under different scanning speeds hardly changes with the scanning speed,and the time temperature gradient at the tail of the melt pool is in direct proportion to the scanning speed.展开更多
Previous studies have revealed that laser power and energy density are significant factors affecting the quality of parts manufactured by selective laser melting(SLM).The normalized equivalent density E_(0)^(*) and di...Previous studies have revealed that laser power and energy density are significant factors affecting the quality of parts manufactured by selective laser melting(SLM).The normalized equivalent density E_(0)^(*) and dimensionless laser power q^(*),which can be regarded as a progress on the understanding of the corresponding dimensional quantities,are adopted in this study to examine the defects,melt pool shape,and primary dendrite spacing of the SLM-manufactured 316 L stainless steel,because it reflects the combined effect of process parameters and material features.It is found that the number of large defects decreases with increasing E_(0)^(*) due to enough heat input during the SLM process,but it will show an increasing trend when excessive heat input(i.e.,utilizing a high E_(0)^(*))is imported into the powder bed.The q^(*) plays an important role in controlling maximum temperature rising in the SLM process,and in turn,it affects the number of large defects.A large q^(*) value results in a low value of absolute frequency of large defects,whereas a maximum value of absolute frequency of large defects is achieved at a low q^(*) even if E_(0)^(*) is very high.The density of the built parts is greater at a higher q^(*) when E_(0)^(*)remains constant.Increasing the melt pool depth at relatively low value of E_(0)^(*) enhances the relative density of the parts.A narrow,deep melt pool can be easily generated at a high q^(*) when E_(0)^(*) is sumciently high,but it may increase melt pool instability and cause keyhole defects.It is revealed that a low E_(0)^(*) can lead to a high cooling rate,which results in a refined primary dendrite spacing.Relatively low E_(0)^(*) is emphasized in selecting the process parameters for the tensile test sample fabrication.It shows that excellent tensile properties,namely ultimate tensile strength,yield strength,and elongation to failure of 773 MPa,584 MPa,and 46%,respectively,can be achieved at a relatively low E_(0)^(*) without heat treatment.展开更多
A thermal conduction model is applied to speed up the numerical analysis of the temperature distribution and the weld pool geometry of full penetration in gas tungsten arc （GTA） welding. With considering both top an...A thermal conduction model is applied to speed up the numerical analysis of the temperature distribution and the weld pool geometry of full penetration in gas tungsten arc （GTA） welding. With considering both top and bottom flee surface deformation of full-penetrated weld pool, three-dimensional weld pool with melting front and solidification front is predicted. Welding experiments are conducted to measure the melting front curves at the top surface and the longitudinal section of the weld. It shows that the predicted and measured results are in good agreement.展开更多
The laser remelting with a two-layer material system (upper material was Al-30 % Ti-20 % Ni alloy,substrate was commercial aluminum alloy) and the laser cladding of a commercial 45 steel with copper Powder (including ...The laser remelting with a two-layer material system (upper material was Al-30 % Ti-20 % Ni alloy,substrate was commercial aluminum alloy) and the laser cladding of a commercial 45 steel with copper Powder (including 25%SiC) were carried out using a 2kW continuous CO2 laser. For the case of laser remelting, a upper Pool in the alloying layer and a lower Pool in the substrate separated by the unmelted Al-Ti-Ni alloy were observed. For laser cladding, a stratified Pool was observed, whose top layer was Cu alloy liquid and bottom was Fe alloy liquid. The mechanism of laser Pool separation and stratification is illustrated by numerical calculation of heat transter process of the two-layer system, combining with material physical properties (especially mixed enthalpy). A classification criterion for laser Pool with the two-layer material system has been presented and four types of the laser Pool are divided into unique Pool, separated Pool, mixed Pool and stratified pool,which provides a theoretical basis for obtaining a excellent surface coating.展开更多
Multi-physics thermo-fluid modeling has been extensively used as an approach to understand melt pool dynamics and defect formation as well as optimizing the process-related parameters of laser powder-bed fusion(L-PBF)...Multi-physics thermo-fluid modeling has been extensively used as an approach to understand melt pool dynamics and defect formation as well as optimizing the process-related parameters of laser powder-bed fusion(L-PBF).However,its capabilities for being implemented as a reliable tool for material design,where minor changes in material-related parameters must be accurately captured,is still in question.In the present research,first,a thermo-fluid computational fluid dynamics(CFD)model is developed and validated against experimental data.Considering the predicted material properties of the pure Mg and commercial ZK60 and WE43 Mg alloys,parametric studies are done attempting to elucidate how the difference in some of the material properties,i.e.,saturated vapor pressure,viscosity,and solidification range,can influence the melt pool dynamics.It is found that a higher saturated vapor pressure,associated with the ZK60 alloy,leads to a deeper unstable keyhole,increasing the keyhole-induced porosity and evaporation mass loss.Higher viscosity and wider solidification range can increase the non-uniformity of temperature and velocity distribution on the keyhole walls,resulting in increased keyhole instability and formation of defects.Finally,the WE43 alloy showed the best behavior in terms of defect formation and evaporation mass loss,providing theoretical support to the extensive use of this alloy in L-PBF.In summary,this study suggests an approach to investigate the effect of materials-related parameters on L-PBF melting and solidification,which can be extremely helpful for future design of new alloys suitable for L-PBF.展开更多
为了预测下封头内双层熔池的流动和传热过程,基于不同湍流模型,同时采用凝固熔化模型对堆芯熔池研究装置(corium pool research apparatus,COPRA)双层熔池实验进行计算流体力学(CFD)数值模拟,通过数值计算获得准稳态下熔池的温度、沿壁...为了预测下封头内双层熔池的流动和传热过程,基于不同湍流模型,同时采用凝固熔化模型对堆芯熔池研究装置(corium pool research apparatus,COPRA)双层熔池实验进行计算流体力学(CFD)数值模拟,通过数值计算获得准稳态下熔池的温度、沿壁面的热流密度与内壁面壳层的分布,将模拟结果与实验值进行比较,评价不同湍流模型的适用性和准确性,并进行湍流模型优选。结果表明,壁面模化大涡模拟(WMLES)湍流模型对下封头内双层熔融池流动与传热模拟的准确性和适用性最好;基于WMLES湍流模型,氧化层温度随着熔池高度增大而增大,氧化层上部存在强烈的湍流,在熔池底部的壳层最厚。展开更多
基金This work was financially supported by the National Key R&D Program of China(Grant No.2017YFB1103900)National Natural Science Foundation of China(Grant No.11972084)+1 种基金National Science and Technology Major Project(2017-VI-0003-0073)Beijing National Science Foundation(1192014).
文摘In this work,the evolution of melt pool under single-point and single-line printing in the laser engineered net shaping(LENS)process is analyzed.Firstly,the basic structure of the melt pool model of the LENS process is established and the necessary assumptions are made.Then,the establishment process of the multi-physical field model of the melt pool is introduced in detail.It is concluded that the simulation model results are highly consistent with the online measurement experiment results in terms of melt pool profile,space temperature gradient,and time temperature gradient.Meanwhile,some parameters,such as the 3D morphology and surface fluid field of the melt pool,which are not obtained in the online measurement experiment,are analyzed.Finally,the influence of changing the scanning speed on the profile,peak temperature,and temperature gradient of the single-line melt pool is also analyzed,and the following conclusions are obtained:With the increase in scanning speed,the profile of the melt pool gradually becomes slender;The relationship between peak temperature and scanning speed is approximately linear in a certain speed range;The space temperature gradient at the tail of the melt pool under different scanning speeds hardly changes with the scanning speed,and the time temperature gradient at the tail of the melt pool is in direct proportion to the scanning speed.
基金supported by the National Natural Science Foundation of China(Grant No.11772344)the National Key R&D Program of China(Project No.2016YFB1100700)。
文摘Previous studies have revealed that laser power and energy density are significant factors affecting the quality of parts manufactured by selective laser melting(SLM).The normalized equivalent density E_(0)^(*) and dimensionless laser power q^(*),which can be regarded as a progress on the understanding of the corresponding dimensional quantities,are adopted in this study to examine the defects,melt pool shape,and primary dendrite spacing of the SLM-manufactured 316 L stainless steel,because it reflects the combined effect of process parameters and material features.It is found that the number of large defects decreases with increasing E_(0)^(*) due to enough heat input during the SLM process,but it will show an increasing trend when excessive heat input(i.e.,utilizing a high E_(0)^(*))is imported into the powder bed.The q^(*) plays an important role in controlling maximum temperature rising in the SLM process,and in turn,it affects the number of large defects.A large q^(*) value results in a low value of absolute frequency of large defects,whereas a maximum value of absolute frequency of large defects is achieved at a low q^(*) even if E_(0)^(*) is very high.The density of the built parts is greater at a higher q^(*) when E_(0)^(*)remains constant.Increasing the melt pool depth at relatively low value of E_(0)^(*) enhances the relative density of the parts.A narrow,deep melt pool can be easily generated at a high q^(*) when E_(0)^(*) is sumciently high,but it may increase melt pool instability and cause keyhole defects.It is revealed that a low E_(0)^(*) can lead to a high cooling rate,which results in a refined primary dendrite spacing.Relatively low E_(0)^(*) is emphasized in selecting the process parameters for the tensile test sample fabrication.It shows that excellent tensile properties,namely ultimate tensile strength,yield strength,and elongation to failure of 773 MPa,584 MPa,and 46%,respectively,can be achieved at a relatively low E_(0)^(*) without heat treatment.
基金The authors are grateful to the financial support for this project from the National Natural Science Foundation of China under grant No. 50475131.
文摘A thermal conduction model is applied to speed up the numerical analysis of the temperature distribution and the weld pool geometry of full penetration in gas tungsten arc （GTA） welding. With considering both top and bottom flee surface deformation of full-penetrated weld pool, three-dimensional weld pool with melting front and solidification front is predicted. Welding experiments are conducted to measure the melting front curves at the top surface and the longitudinal section of the weld. It shows that the predicted and measured results are in good agreement.
文摘The laser remelting with a two-layer material system (upper material was Al-30 % Ti-20 % Ni alloy,substrate was commercial aluminum alloy) and the laser cladding of a commercial 45 steel with copper Powder (including 25%SiC) were carried out using a 2kW continuous CO2 laser. For the case of laser remelting, a upper Pool in the alloying layer and a lower Pool in the substrate separated by the unmelted Al-Ti-Ni alloy were observed. For laser cladding, a stratified Pool was observed, whose top layer was Cu alloy liquid and bottom was Fe alloy liquid. The mechanism of laser Pool separation and stratification is illustrated by numerical calculation of heat transter process of the two-layer system, combining with material physical properties (especially mixed enthalpy). A classification criterion for laser Pool with the two-layer material system has been presented and four types of the laser Pool are divided into unique Pool, separated Pool, mixed Pool and stratified pool,which provides a theoretical basis for obtaining a excellent surface coating.
基金the financial supports received from Wenner-Gren foundation(UPD2021-0229),JernkontoretSTT(Stiftelsen för Tillämpad Termodynamik).
文摘Multi-physics thermo-fluid modeling has been extensively used as an approach to understand melt pool dynamics and defect formation as well as optimizing the process-related parameters of laser powder-bed fusion(L-PBF).However,its capabilities for being implemented as a reliable tool for material design,where minor changes in material-related parameters must be accurately captured,is still in question.In the present research,first,a thermo-fluid computational fluid dynamics(CFD)model is developed and validated against experimental data.Considering the predicted material properties of the pure Mg and commercial ZK60 and WE43 Mg alloys,parametric studies are done attempting to elucidate how the difference in some of the material properties,i.e.,saturated vapor pressure,viscosity,and solidification range,can influence the melt pool dynamics.It is found that a higher saturated vapor pressure,associated with the ZK60 alloy,leads to a deeper unstable keyhole,increasing the keyhole-induced porosity and evaporation mass loss.Higher viscosity and wider solidification range can increase the non-uniformity of temperature and velocity distribution on the keyhole walls,resulting in increased keyhole instability and formation of defects.Finally,the WE43 alloy showed the best behavior in terms of defect formation and evaporation mass loss,providing theoretical support to the extensive use of this alloy in L-PBF.In summary,this study suggests an approach to investigate the effect of materials-related parameters on L-PBF melting and solidification,which can be extremely helpful for future design of new alloys suitable for L-PBF.
基金supported by the Natu⁃ral Science Foundation of Shandong Province(No.ZR2021QE230)the Talent Research Project of Qilu Uni⁃versity of Technology(Shandong Academy of Sciences)(No.2023RCKY118)the National Natural Science Foundation of China(Nos.52275438,52205480).
文摘为了预测下封头内双层熔池的流动和传热过程,基于不同湍流模型,同时采用凝固熔化模型对堆芯熔池研究装置(corium pool research apparatus,COPRA)双层熔池实验进行计算流体力学(CFD)数值模拟,通过数值计算获得准稳态下熔池的温度、沿壁面的热流密度与内壁面壳层的分布,将模拟结果与实验值进行比较,评价不同湍流模型的适用性和准确性,并进行湍流模型优选。结果表明,壁面模化大涡模拟(WMLES)湍流模型对下封头内双层熔融池流动与传热模拟的准确性和适用性最好;基于WMLES湍流模型,氧化层温度随着熔池高度增大而增大,氧化层上部存在强烈的湍流,在熔池底部的壳层最厚。
