EI、Scopus 收录
中文核心期刊
Liu Hailin, Yi Min, Wang Jianxiang, Yi Xin. Numerical simulations of powder spreading process in selective laser melting and powder layer characterization. Chinese Journal of Theoretical and Applied Mechanics, 2023, 55(9): 1921-1938. DOI: 10.6052/0459-1879-22-589
Citation: Liu Hailin, Yi Min, Wang Jianxiang, Yi Xin. Numerical simulations of powder spreading process in selective laser melting and powder layer characterization. Chinese Journal of Theoretical and Applied Mechanics, 2023, 55(9): 1921-1938. DOI: 10.6052/0459-1879-22-589

NUMERICAL SIMULATIONS OF POWDER SPREADING PROCESS IN SELECTIVE LASER MELTING AND POWDER LAYER CHARACTERIZATION

  • Received Date: December 13, 2022
  • Accepted Date: July 03, 2023
  • Available Online: July 04, 2023
  • As an advanced metal additive manufacturing technology, selective laser melting (SLM) is capable of fabricating metal components rapidly with excellent mechanical properties and complex geometries. One of key foundations for producing high-performance components using SLM is a relatively uniform distribution of metal powder particles in compact powder layers, which is affected by powder flowability, powder spreading speed, and layer thickness. Here, the discrete element modeling for obtaining particle properties, analyzing effects of spreading processes on powder layer quantity and efficient simulations on the multi-layer spreading process are performed. The rolling friction coefficient and surface energy density of tungsten particles are obtained by comparing experimental and numerical results of repose angle and relative density of the tungsten powder pile. Effects of rolling friction coefficient and surface energy density on particle flowability are revealed, and all physical parameters of tungsten particles required in the discrete element modeling are obtained. Effects of powder layer thickness and spreading speed on the layer quality are quantitatively examined based on the discrete element modeling of single-layer spreading process. Through evaluation on packing density, coordination number distribution, layer surface roughness and layer uniformity, the spreading process window is determined for a powder layer consisting of closely and uniformly distributed metal powder particles. By identifying completely unfused metal powder particles in the melted powder bed, a new discrete element model capable of efficiently simulating the multi-layer spreading process in a physical way is established. In the new discrete element model, rough surfaces of fused metal parts are characterized accurately, and completely unfused metal powder particles are represented by movable spherical particles which enables the elimination of unphysical limitation of the movement of completely unfused metal powder particles. Having these advantages, the new discrete element model significantly improves the efficiency and fidelity of simulations on the multi-layer spreading process.
  • [1]
    Wan HY, Zhou ZJ, Li CP, et al. Effect of scanning strategy on mechanical properties of selective laser melted Inconel 718. Materials Science & Engineering A, 2019, 753: 42-48
    [2]
    Ren X, Liu H, Lu F, et al. Effects of processing parameters on the densification, microstructures and mechanical properties of pure tungsten fabricated by optimized selective laser melting: From single and multiple scan tracks to bulk parts. International Journal of Refractory Metals and Hard Materials, 2021, 96: 105490 doi: 10.1016/j.ijrmhm.2021.105490
    [3]
    Ren X, Peng H, Li J, et al. Selective electron beam melting (SEBM) of pure tungsten: Metallurgical defects, microstructure, texture and mechanical properties. Materials, 2022, 15: 1172 doi: 10.3390/ma15031172
    [4]
    陈泽坤, 蒋佳希, 王宇嘉等. 金属增材制造中的缺陷、组织形貌和成形材料力学性能. 力学学报, 2021, 53: 3190-3205 (Chen Zekun, Jiang Jiaxi, Wang Yujia, et al. Defects, microstructures and mechanical properties of materials fabricated by metal additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3190-3205 (in Chinese)

    Chen Zekun, Jiang Jiaxi, Wang Yujia, et al. Defects, microstructures and mechanical properties of materials fabricated by metal additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3190-3205 (in Chinese)
    [5]
    Lu F, Wan H, Ren X, et al. Mechanical and microstructural characterization of additive manufactured Inconel 718 alloy by selective laser melting and laser metal deposition. Journal of Iron and Steel Research International, 2022, 29: 1322-1333 doi: 10.1007/s42243-022-00755-x
    [6]
    廉艳平, 刘谋斌. 金属增材制造中的关键力学问题与前沿计算技术主题序. 力学学报, 2021, 53: 3179-3180 (Lian Yanping, Liu Mobin. Computational study of evolution and fatigue dispersity of microstructures by additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3179-3180 (in Chinese)

    Lian Yanping, Liu Mobin. Computational study of evolution and fatigue dispersity of microstructures by additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3179-3180 (in Chinese)
    [7]
    孙远远, 江五贵, 徐高贵等. 选区激光熔化成形区粗糙表面对铺粉质量的影响: 离散元模拟. 力学学报, 2021, 53: 3217-3227 (Sun Yuanyuan, Jiang Wugui, Xu Gaogui, et al. Influence of rough surface of deposited area on quality of powder spreading during selective laser melting: Discrete element simulations. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3217-3227 (in Chinese)

    Sun Yuanyuan, Jiang Wugui, Xu Gaogui, et al. Influence of rough surface of deposited area on quality of powder spreading during selective laser melting: Discrete element simulations. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3217-3227 (in Chinese)
    [8]
    陈辉, 阎文韬. 激光选区熔化增材制造中的粉体热动力学行为. 力学学报, 2021, 53: 3206-3216 (Chen Hui, Yan Wentao. Dynamic behaviours of powder particles in selective laser melting additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3206-3216 (in Chinese)

    Chen Hui, Yan Wentao. Dynamic behaviours of powder particles in selective laser melting additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3206-3216 (in Chinese)
    [9]
    Jiang WG, Xu G, Li Q, Improvement of wetting and necking of nickel-based superalloys fabricated by sequential dual-laser powder bed fusion via particle-scale computational fluid dynamics. Additive Manufacturing, 2022, 59: 103203
    [10]
    Liu H, Pang J, Wang J, et al. New heat source model for accurate estimation of laser energy absorption near free surface in selective laser melting. Extreme Mechanics Letters, 2022, 56: 101894 doi: 10.1016/j.eml.2022.101894
    [11]
    易敏, 常珂, 梁晨光等. 增材制造微结构演化及疲劳分散性计算. 力学学报, 2021, 53: 3263-3273 (Yi Min, Chang Ke, Liang Chenguang, et al. Computational study of evolution and fatigue dispersity of microstructures by additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3263-3273 (in Chinese)

    Yi Min, Chang Ke, Liang Chenguang, et al. Computational study of evolution and fatigue dispersity of microstructures by additive manufacturing. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53: 3263-3273 (in Chinese)
    [12]
    Shao J, Yu G, He X, et al. Grain size evolution under different cooling rate in laser additive manufacturing of superalloy. Optics & Laser Technology, 2019, 119: 105662
    [13]
    Zhao Z, Li L, Tan L, et al. Simulation of stress field during the selective laser melting process of the nickel-based superalloy, GH4169. Materials, 2018, 11: 1525
    [14]
    Meier C, Weissbach R, Weinberg J, et al. Modeling and characterization of cohesion in fine metal powders with a focus on additive manufacturing process simulations. Powder Technology, 2019, 343: 855-866 doi: 10.1016/j.powtec.2018.11.072
    [15]
    Mussatto A, Groarke R, O’Neill A, et al. Influences of powder morphology and spreading parameters on the powder bed topography uniformity in powder bed fusion metal additive manufacturing. Additive Manufacturing, 2021, 38: 101807 doi: 10.1016/j.addma.2020.101807
    [16]
    Ma Y, Evans TM, Philips N, et al. Numerical simulation of the effect of fine fraction on the flowability of powders in additive manufacturing. Powder Technology, 2020, 360: 608-621 doi: 10.1016/j.powtec.2019.10.041
    [17]
    Yao D, Liu X, Wang J, et al. Numerical insights on the spreading of practical 316 L stainless steel powder in SLM additive manufacturing. Powder Technology, 2021, 390: 197-208 doi: 10.1016/j.powtec.2021.05.082
    [18]
    Chen H, Chen Y, Liu Y, et al. Packing quality of powder layer during counter-rolling-type powder spreading process in additive manufacturing. International Journal of Machine Tools and Manufacture, 2020, 153: 103553 doi: 10.1016/j.ijmachtools.2020.103553
    [19]
    Parteli EJR, Pöschel T. Particle-based simulation of powder application in additive manufacturing. Powder Technology, 2016, 288: 96-102 doi: 10.1016/j.powtec.2015.10.035
    [20]
    Nan W, Pasha M, Ghadiri M. Effect of gas-particle interaction on roller spreading process in additive manufacturing. Powder Technology, 2020, 372: 466-476 doi: 10.1016/j.powtec.2020.05.119
    [21]
    Yao D, An X, Fu H, et al. Dynamic investigation on the powder spreading during selective laser melting additive manufacturing. Additive Manufacturing, 2021, 37: 101707 doi: 10.1016/j.addma.2020.101707
    [22]
    Marchais K, Girardot J, Metton C, et al. A 3D DEM simulation to study the influence of material and process parameters on spreading of metallic powder in additive manufacturing. Computational Particle Mechanics, 2021, 8: 943-953 doi: 10.1007/s40571-020-00380-z
    [23]
    Fouda YM, Bayly AE. A DEM study of powder spreading in additive layer manufacturing. Granular Matter, 2020, 22: 10 doi: 10.1007/s10035-019-0971-x
    [24]
    Wu Q, Qiao C, Wang J, et al. Adaptability investigations on bottom modified blade in powder spreading process of additive manufacturing. Additive Manufacturing, 2022, 49: 102477 doi: 10.1016/j.addma.2021.102477
    [25]
    Wang L, Li EL, Shen H, et al. Adhesion effects on spreading of metal powders in selective laser melting. Powder Technology, 2020, 363: 602-610 doi: 10.1016/j.powtec.2019.12.048
    [26]
    Lee Y, Gurnon AK, Bodner D, et al. Effect of particle spreading dynamics on powder bed quality in metal additive manufacturing. Integrating Materials and Manufacturing Innovation, 2020, 9: 410-422 doi: 10.1007/s40192-020-00193-1
    [27]
    Wu S, Lei Z, Jiang M, et al. Experimental investigation and discrete element modeling for particle-scale powder spreading dynamics in powder-bed-fusion-based additive manufacturing. Powder Technology, 2022, 403: 117390 doi: 10.1016/j.powtec.2022.117390
    [28]
    He Y, Hassanpour A, Bayly AE. Linking particle properties to layer characteristics: Discrete element modelling of cohesive fine powder spreading in additive manufacturing. Additive Manufacturing, 2020, 36: 101685 doi: 10.1016/j.addma.2020.101685
    [29]
    Si L, Zhang T, Zhou M, et al. Numerical simulation of the flow behavior and powder spreading mechanism in powder bed-based additive manufacturing. Powder Technology, 2021, 394: 1004-1016 doi: 10.1016/j.powtec.2021.09.010
    [30]
    Chen H, Wei Q, Zhang Y, et al. Powder-spreading mechanisms in powder-bed-based additive manufacturing: Experiments and computational modeling. Acta Materialia, 2019, 179: 158-171 doi: 10.1016/j.actamat.2019.08.030
    [31]
    Yao D, Wang J, Li M, et al. Segregation of 316L stainless steel powder during spreading in selective laser melting based additive manufacturing. Powder Technology, 2022, 397: 117096 doi: 10.1016/j.powtec.2021.117096
    [32]
    Xiang Z, Yin M, Deng Z, et al. Simulation of forming process of powder bed for additive manufacturing. Journal of Manufacturing Science and Engineering, 2016, 138: 081002 doi: 10.1115/1.4032970
    [33]
    Lampitella V, Trofa M, Astarita A, et al. Discrete element method analysis of the spreading mechanism and its influence on powder bed characteristics in additive manufacturing. Micromachines, 2021, 12: 392 doi: 10.3390/mi12040392
    [34]
    Zhang J, Tan Y, Xiao X, et al. Comparison of roller-spreading and blade-spreading processes in powder-bed additive manufacturing by DEM simulations. Particuology, 2022, 66: 48-58 doi: 10.1016/j.partic.2021.07.005
    [35]
    Haeri S, Wang Y, Ghitab O, et al. Discrete element simulation and experimental study of powder spreading process in additive manufacturing. Powder Technology, 2017, 306: 45-54 doi: 10.1016/j.powtec.2016.11.002
    [36]
    Xiang Z, Zhang M, Yan R, et al. Powder-spreading dynamics and packing quality improvement for laser powder bed fusion additive manufacturing. Powder Technology, 2021, 389: 278-291 doi: 10.1016/j.powtec.2021.05.036
    [37]
    Wang L, Yu A, Li E, et al. Effects of spreader geometry on powder spreading process in powder bed additive manufacturing. Powder Technology, 2021, 384: 211-222 doi: 10.1016/j.powtec.2021.02.022
    [38]
    Wang L, Zhou Z, Li E, et al. Powder deposition mechanism during powder spreading with different spreader geometries in powder bed fusion additive manufacturing. Powder Technology, 2022, 395: 802-810 doi: 10.1016/j.powtec.2021.10.017
    [39]
    Ahmed M, Pasha M, Nan W, et al. A simple method for assessing powder sspreadability for additive manufacturing. Powder Technology, 2020, 367: 671-679 doi: 10.1016/j.powtec.2020.04.033
    [40]
    Nan W, Pasha M, Bonakdar T, et al. Jamming during particle spreading in additive manufacturing. Powder Technology, 2018, 338: 253-262 doi: 10.1016/j.powtec.2018.07.030
    [41]
    Yang RY, Zou RP, Yu AB, et al. Pore structure of the packing of fine particles. Journal of Colloid and Interface Science, 2006, 299: 719-725 doi: 10.1016/j.jcis.2006.02.041
    [42]
    Hertz H. Uber die Berührung fester elastischer Körper (on the contact of elastic solids). Journal für die reine und angewandte Mathematik, 1882, 92: 156-171
    [43]
    Mindlin RD. Compliance of elastic bodies in contact. Journal of Applied Mechanics, 1949, 16: 259-268 doi: 10.1115/1.4009973
    [44]
    Mindlin RD, Deresiewicz H. Elastic spheres in contact under varying oblique forces. Journal of Applied Mechanics, 1953, 20: 327-344 doi: 10.1115/1.4010702
    [45]
    Yan W, Qian Y, Ge W, et al. Meso-scale modeling of multiple-layer fabrication process in selective electron beam melting: Inter-layer/track voids formation. Materials & Design, 2018, 141: 210-219
    [46]
    Shaheen MY, Thornton AR, Luding S, et al. The influence of material and process parameters on powder spreading in additive manufacturing. Powder Technology, 2021, 383: 564-583 doi: 10.1016/j.powtec.2021.01.058
    [47]
    Johnson KL, Kendall K, Roberts AD. Surface energy and the contact of elastic solids. Proceedings of the Royal Society of London A, 1971, 324: 301-313
    [48]
    孙其诚, 王光谦. 颗粒物质力学导论. 北京: 科学出版社, 2009

    Sun Qicheng, Wang Guangqian. Mechanics of Granular Matter. Beijing: Science Press, 2009 (in Chinese)
    [49]
    Chang H, Huang Z, Wen S, et al. The influence of crystal defects on the elastic properties of tungsten metals. Fusion Engineering and Design, 2016, 109-111: 321-325 doi: 10.1016/j.fusengdes.2016.03.003
    [50]
    Grünwald E, Nuster R, Treml R, et al. Young’s modulus and Poisson’s ratio characterization of tungsten thin films via laser ultrasound. Materials Today: Proceedings, 2015, 2: 4289-4294 doi: 10.1016/j.matpr.2015.09.015
    [51]
    Chen H, Xiao YG, Liu YL, et al. Effect of Young’s modulus on DEM results regarding transverse mixing of particles within a rotating drum. Powder Technology, 2017, 318: 507-517 doi: 10.1016/j.powtec.2017.05.047
    [52]
    Kobayashi T, Tanaka T, Shimada N, et al. DEM-CFD analysis of fluidization behavior of Geldart Group A particles using a dynamic adhesion force model. Powder Technology, 2013, 248: 143-152 doi: 10.1016/j.powtec.2013.02.028
    [53]
    Hærvig J, Kleinhans U, Wieland C, et al. On the adhesive JKR contact and rolling models for reduced particle stiffness discrete element simulations. Powder Technology, 2017, 319: 472-482 doi: 10.1016/j.powtec.2017.07.006
    [54]
    Washino K, Chan EL, Tanaka T. DEM with attraction forces using reduced particle stiffness. Powder Technology, 2018, 35: 202-208
    [55]
    Oropeza D, Penny RW, Gilbert D, et al. Mechanized spreading of ceramic powder layers for additive manufacturing characterized by transmission x-ray imaging: Influence of powder feedstock and spreading parameters on powder layer density. Powder Technology, 2022, 398: 117053 doi: 10.1016/j.powtec.2021.117053
    [56]
    Mindt HW, Megahed M, Lavery NP, et al. Powder bed layer characteristics: The overseen first-order process input. Metallurgical and Materials Transactions A, 2016, 47: 3811-3822 doi: 10.1007/s11661-016-3470-2
    [57]
    Mindt HW, Desmaison O, Megahed M, et al. Modeling of powder bed manufacturing defects. Journal of Materials Engineering and Performance, 2018, 27: 32-43 doi: 10.1007/s11665-017-2874-5
    [58]
    Gu D, Xia M, Dai D. On the role of powder flow behavior in fluid thermodynamics and laser process ability of Ni-based composites by selective laser melting. International Journal of Machine Tools and Manufacture, 2019, 137: 67-78 doi: 10.1016/j.ijmachtools.2018.10.006
    [59]
    Zhao Y, Chew JW. Effect of lognormal particle size distributions on particle spreading in additive manufacturing. Advanced Powder Technology, 2021, 32: 1127-1144 doi: 10.1016/j.apt.2021.02.019
    [60]
    Haeri S. Optimisation of blade type spreaders for powder bed preparation in additive manufacturing using DEM simulations. Powder Technology, 2017, 321: 94-104 doi: 10.1016/j.powtec.2017.08.011
    [61]
    Kovalev OB, Gusarov AV, Belyaev VV. Morphology of random packing of microparticles and its effect on the absorption of laser radiation during selective melting of powders. International Journal of Engineering Science, 2020, 157: 103378 doi: 10.1016/j.ijengsci.2020.103378
    [62]
    Nan W, Pasha M, Ghadiri M. Numerical simulation of particle flow and segregation during roller spreading process in additive manufacturing. Powder Technology, 2020, 364: 811-821 doi: 10.1016/j.powtec.2019.12.023
  • Related Articles

    [1]Zhi Peng, Wu Yuching. GRAPH NEURAL NETWORKS ACCELERATED GRANULAR FLOW BASED ON DISCRETE ELEMENT METHOD[J]. Chinese Journal of Theoretical and Applied Mechanics, 2024, 56(12): 3601-3611. DOI: 10.6052/0459-1879-24-269
    [2]Li Wen, Liu Qipeng, Gao Yuehua, Chu Xihua, Zhang Zhao, Wang Zhenjun. INVESTIGATION INTO SLM BLADE INCLINATION EFFECT ON POWDER SPREADING BEHAVIOR BASED ON DISCRETE ELEMENT METHOD[J]. Chinese Journal of Theoretical and Applied Mechanics, 2024, 56(3): 774-784. DOI: 10.6052/0459-1879-23-462
    [3]Zhang Wei, Xiao Weijian, Yuan Chuanniu, Zhang Ning, Liu Kun. EFFECT OF PARTICLE SIZE DISTRIBUTION ON FORCE CHAIN EVOLUTION MECHANISM IN IRON POWDER COMPACTION BY DISCRETE ELEMENT METHOD[J]. Chinese Journal of Theoretical and Applied Mechanics, 2022, 54(9): 2489-2500. DOI: 10.6052/0459-1879-22-204
    [4]Sun Yuanyuan, Jiang Wugui, Xu Gaogui, Chen Tao, Mao Longhui. INFLUENCE OF ROUGH SURFACE OF DEPOSITED AREA ON QUALITY OF POWDER SPREADING DURING SELECTIVE LASER MELTING: DISCRETE ELEMENT SIMULATIONS[J]. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53(12): 3217-3227. DOI: 10.6052/0459-1879-21-399
    [5]Chen Hui, Yan Wentao. DYNAMIC BEHAVIOURS OF POWDER PARTICLES IN SELECTIVE LASER MELTING ADDITIVE MANUFACTURING[J]. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53(12): 3206-3216. DOI: 10.6052/0459-1879-21-403
    [6]Duan Zongyang, Zhao Yunhua, Xu Zhang. CHARACTERIZATION OF NEAR-WALL PARTICLE DYNAMICS BASED ON DISCRETE ELEMENT METHOD ANDARTIFICIAL NEURAL NETWORK[J]. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53(10): 2656-2666. DOI: 10.6052/0459-1879-21-313
    [7]Zhang Jiangtao, Tan Yuanqiang, Ji Caiyuan, Xiao Xiangwu, Jiang Shengqiang. RESEARCH ON THE EFFECTS OF ROLLER-SPREADING PARAMETERS FOR NYLON POWDER SPREADABILITY IN ADDITIVE MANUFACTURING[J]. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53(9): 2416-2426. DOI: 10.6052/0459-1879-21-240
    [8]Tan Yuanqiang, Xiao iangwu, Zhang Jiangtao, Jiang Shengqiang. DETERMINATION OF DISCRETE ELEMENT MODEL CONTACT PARAMETERS OF NYLON POWDER AT SLS PREHEATING TEMPERATURE AND ITS FLOW CHARATERISTICS[J]. Chinese Journal of Theoretical and Applied Mechanics, 2019, 51(1): 56-63. DOI: 10.6052/0459-1879-18-341
    [9]Wang Zenghui, Li Xikui. MESO-MECHANICALLY INFORMED MACROSCOPIC CHARACTERIZATION OF DAMAGE-HEALING-PLASTICITY FOR GRANULAR MATERIALS[J]. Chinese Journal of Theoretical and Applied Mechanics, 2018, 50(2): 284-296. DOI: 10.6052/0459-1879-17-362
    [10]Xue Huaqing, Xu Ruina, Jiang Peixue, Zhou Shangwen. CHARACTERIZATION OF ROCK MICROSTRUCTURE USING 3D X-RAY COMPUTED TOMOGRAPHY[J]. Chinese Journal of Theoretical and Applied Mechanics, 2015, 47(6): 1073-1078. DOI: 10.6052/0459-1879-15-102
  • Cited by

    Periodical cited type(1)

    1. 李雯,刘其鹏,高月华,楚锡华,张昭,王振军. 基于离散元法的SLM刮刀倾角对粉末铺展行为的影响研究. 力学学报. 2024(03): 774-784 . 本站查看

    Other cited types(1)

Catalog

    Article Metrics

    Article views (737) PDF downloads (127) Cited by(2)
    Related

    /

    DownLoad:  Full-Size Img  PowerPoint
    Return
    Return