Research Progress on the Numerial Simulation of a Melting Pool Coupling of Light-Powder and Gas-Liquid Interface Tracking by Coaxial Powder Metal Laser 3D Printing
AN Xiaolong, LYU Yunzhuo, QIN Zuoxiang, LU Xing
School of Material Science and Engineering, Dalian Jiaotong University, Dalian 116028
Abstract: As a “toolless” digital manufacturing technology, metal laser 3D printing that get rid of the limitation of traditional processing methods is very likely to change the production mode of products and highly benefit the social and consumers. The 3D printing technology makes the high precision complex structure manufacturing possible through the precision machining mode of layer stacking, which will consumedly simplify the pro-duct design process, improve the integration of components and accelerate the producting cycles. Furthermore, compared to the “subtract mate-rial manufacturing” of blanks with cutting machines, 3D printing technology can reduce the amount of raw materials and greatly relieve the pressure of natural environment. Actually, 3D printing manufacturing is a “point by point scanning-line by line lapping-layer by layer stacking” cyclic process. During the process of the long time manufacturing, different parts of the material have went through a series of micro-heat treatment processes,including short-term temperature changes, unstable state, strong constraint and cyclic solid phase transition . The heating and cooling rate of these micro-heat treatments are extremely fast and the time of phase transition is very short. And the phase transition temperature, heating and cooling rate and phase transition duration of each micro-heat treatment change with the number of thermal cycles. Thus, the laser 3D printed metal components obtain a unique microstructure and exhibit a strong dependence on the processing conditions, which in turn affects the mecha-nical properties of the molded parts. Therefore, achieving the active control of the microstructure and metallurgical defects of laser 3D printed metal parts is crucial issue to be solved. The mastering of the coupling effect of the powder flow and the laser beam in the 3D printing process of the coaxial powder feeding metal laser, and the mass transfer and expansion characteristics of the gas-liquid free interface of the molten pool are the pivotal to select the optimal processing parameters and hence lead to an excellent mechanical properties of the metal. However, it is hard to accurately and quantitatively reveal the above problems by the means of experimental analysis. Yet the numerical simulation is capable of effectively revealing the microscopic laws . For example, in the aspect of light-powder coupling, most researchers currently study the interaction mechanism between laser beam and powder from the perspective of laser beam attenuation from single powder particle to powder flow. On the other hand, other researchers establish the mathematical model from the perspective of powder particle absorption and scattering to the laser beam, and adopt the Mie scattering theory and the Lambert-Beer law to analyse and calculate the interaction between the powder flow and the laser beam. Howe-ver, the reports revolve round numerical models including multi-angle and multi-factors such as powder flow attenuation on laser beam and absorption of powder flow and reflection and scattering of laser light is rare, therefore, the above aspects will be the main research direction of scholars in the future. This paper mainly reviews the research progress of 3D printing simulations of coaxial powder metal laser in domestic and foreign research scho-lars, and elaborates the light-powder coupling, the gas-liquid interface and the solid-liquid interface tracking algorithm etc in the 3D printing process.
安晓龙, 吕云卓, 覃作祥, 陆兴. 同轴送粉激光3D打印光粉耦合作用以及熔池气液界面追踪数值模拟的研究进展[J]. 材料导报, 2019, 33(1): 167-174.
AN Xiaolong, LYU Yunzhuo, QIN Zuoxiang, LU Xing. Research Progress on the Numerial Simulation of a Melting Pool Coupling of Light-Powder and Gas-Liquid Interface Tracking by Coaxial Powder Metal Laser 3D Printing. Materials Reports, 2019, 33(1): 167-174.
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2019, Vol. 33 
