Progress in Numerical Simulation of Laser 3D Printing of Metal by Coaxial Powder Feeding: Flow in Welding Pool, Composition Distribution and Tissue Growth
AN Xiaolong, LYU Yunzhuo, QIN Zuoxiang, LU Xing
School of Material Science and Engineering, Dalian Jiaotong University, Dalian 116028
Abstract: In the exceptional historical opportunity of “Made in China 2025”, the “National Advanced Manufacturing Strategic Plan” of the United States, the “Amazing Plan” of European Space Agency, the Japanese “Additive Manufacturing Research Program”, the “Industrial Additive Manufacturing Project” in Singapore and the EU “3D Printing Standardization Roadmap”, the metal laser 3D printing has become the focus of research among scholars at home and abroad. Metal laser 3D printing is a technique that integrate computer-aided design, material processing and forming technology, and manufacture products by stacking and solidifying special materials through software and numerical control system based on the digital model files. Different from traditional machining mode of cutting and assembling raw materials, it is a innovative technique that manufacture products from scratch based on the materials accumulation principle. Just because of the technological characteristics of addictive manufacturing, it has attracted worldwide attention, and will evoke a series of profound changes to the traditional manufacturing industry.The coaxial powder feeding type me-tal laser 3D printing technique possesses broad application prospects in the field of aviation, aerospace, transportation, medical treatment and energy, because of its large forming size, wide range of available materials and excellent material properties of shaped parts, which has become the main stream technology of additive manufacturing. There are complex dynamic physical metallurgical processesincluding heat transfer, convection, mass transfer, gas-liquid interface metallurgy and solid-liquid interface diffusion in the 3D printing pool. The fluid dynamic behavior of the weld pool directly affects the homogeneity and compactness of the material structure. Therefore, there still exist several key problems to be figured out in me-tal laser 3D printing, which are the simulation of the fluid dynamic process of the weld pool by fluid mechanics, establishment of three-dimensional unsteady model of the temperature and flow field of the weld pool, the influence of buoyancy, surface tension, powder impact force on the temperature field, velocity field and molten pool shape of 3D printing. Numerical simulation is one of the important methods to study the dynamic processin the welding pool of co-axial powder feeding metal laser 3D printing. At present, research on the numerical simulations of coaxial powder laser metal 3D printing and laser wel-ding have included more comprehensive multiscale numerical models, such as light-powder coupling numerical model of molten pool, the interface tracing model of gas-liquid interface and solid-liquid mixed zone in molten pool, the temperature field and fluid flow analysis model of instantaneous variation of molten pool, the mesoscopic model for the distribution of alloying elements in the molten pool and the model for the morphology of the molten pool and the cellular automata for microstructure solidification based on the phase field method. This article mainly elaborates the domestic and international researches on simulation of the coaxial powder metal laser 3D prin-ting, which mainly focus on the analysis of thermal field and flow field with instantaneous variations in the molten pool, the distribution process of the alloying elements, the morphology of the molten pool and solidification of the microstructure during the 3D prin-ting process. Owing to the universal applicability of numerical simulation method and in order to introduce the numerical simulation methods related to coaxial powder feeding metal laser 3D printing technique in a more comprehensive manner, this article also involves a small amount of numerical simulation about coaxial powder laser cladding and laser arc welding.
安晓龙, 吕云卓, 覃作祥, 陆兴. 同轴送粉金属激光3D打印熔池流动、成分分布以及组织生长数值模拟的研究进展[J]. 材料导报, 2018, 32(21): 3743-3753.
AN Xiaolong, LYU Yunzhuo, QIN Zuoxiang, LU Xing. Progress in Numerical Simulation of Laser 3D Printing of Metal by Coaxial Powder Feeding: Flow in Welding Pool, Composition Distribution and Tissue Growth. Materials Reports, 2018, 32(21): 3743-3753.
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2018, Vol. 32 
