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Numerical Study of Grain Growth in Laser Powder Bed Fusion Additive Manufacturing of Metals

Department of Mechanical and Aerospace Engineering, Case Western Reserve University, 10900 Euclid Avenue, Cleveland, Ohio 44106, USA

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Zongyue Fan

Department of Mechanical and Aerospace Engineering, Case Western Reserve University, 10900 Euclid Avenue, Cleveland, Ohio 44106, USA

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Hao Wang

Department of Mechanical and Aerospace Engineering, Case Western Reserve University, 10900 Euclid Avenue, Cleveland, Ohio 44106, USA

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, and

Bo Li

https://orcid.org/0000-0002-0127-8210

Department of Mechanical and Aerospace Engineering, Case Western Reserve University, 10900 Euclid Avenue, Cleveland, Ohio 44106, USA

E-mail Address: bxl295@case.edu

Corresponding author.

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https://doi.org/10.1142/S0219876221410127Cited by:0 (Source: Crossref)

This article is part of the issue:

Special Issue: ICCM 2020, Part 2
Guest Editor: Eric Li

Abstract

Laser Powder Bed Fusion (LPBF) is an additive manufacturing method that manufactures high density and quality metal products. We present a coupled grain growth and heat transfer modeling technique to understand the materials microstructure evolution in metals during the cooling process of LPBF. The phase-field model is combined with a transient heat transfer equation to simulate the solidification and crystallization of the melt pool simultaneously. Specifically, the variable domain and driving force of the order parameters in the phase-field calculation are defined using current temperature distribution. Additionally, the latent heat generated by crystallization is introduced as a heat source to affect temperature evolution in the cooling process. The finite element method with a staggering strategy is employed to solve the coupled governing equations on an irregular computational domain. The computational framework is verified in a one-dimensional solidification problem by comparing the velocity of the fluid-solid interface. The two-way coupling solution of solidification and crystallization is studied in an example of LPBF of Aluminum alloys.

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