3D thermal modelling and simulation of selective laser melting

Abstract

Selective laser melting (SLM) is the most common additive manufacturing (AM) method since its manufacturing abilities for metal parts. In this study, heat transfer modelling and multi-track simulations of SLM with different parameters were conducted to predict maximum temperatures and melt pool dimensions depends on parameters such as laser power, scanning speed and hatching distance. Heat transfer equations for selective laser melting was obtained and material properties was revealed as temperature dependent. Goldak volumetric laser heat source model was used as the flux source. Finite Element Analysis (FEA) simulations for different laser power, scanning speed and hatching distance were conducted in ABAQUS FEA software as it provides a parametric job possibility within its Fortran subroutines. During laser scanning, it was concluded in simulation results that powder material is melted by heat source through at least one layer and this leads interlayer connection.  Moreover, maximum temperatures were found stable from the beginning to the end of the track until it achieves equilibrium regime in view of temperature distribution. Lastly melt pool dimensions/ dimension ratios were examined comparing to the literature.