This paper presents a 3D transient finite element (FE) model of laser solid freeform fabrication (LSFF) process. The proposed model determines the thermal distribution throughout the workpiece as a function of time and process parameters including laser power, traverse speed, and material properties. Based on the thermal analysis, the clad formation is then predicted. In the proposed method, the thermal domain is numerically obtained, assuming the interaction between the laser beam and powder stream is to be decoupled. Once the melt pool boundary is obtained, the physical domain is discretized in a cross-sectional direction. Based on the powder feed rate, elapsed time, and intersection of the melt pool and powder stream area, layers of additive material are then added onto the non-planar domain. In the numerical simulation, the effects of a non-planar surface on the process parameters such as powder efficiency and absorption factor are taken into account. The model was used to predict the geometrical and thermal properties of a four-layer thin wall of AISI 4340 steel. Numerical results show that the temperatures increase sensibly at the end-segments of layers 2, 3, and 4. Experimental and numerical results are compared to verify the accuracy and reliability of the proposed model.
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ICALEO 2006: 25th International Congress on Laser Materials Processing and Laser Microfabrication
October 30–November 2, 2006
Scottsdale, Arizona, USA
ISBN:
978-0-912035-85-7
PROCEEDINGS PAPER
On the 3D modeling of geometrical formation in laser solid freeform fabrication process
Masoud Alimardani;
Masoud Alimardani
1
Department of Mechanical Engineering, University of Waterloo
200 University Avenue W., Waterloo, Ontario, N2L 3G1, Canada
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Ehsan Toyserkani
Ehsan Toyserkani
1
Department of Mechanical Engineering, University of Waterloo
200 University Avenue W., Waterloo, Ontario, N2L 3G1, Canada
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Published Online:
October 01 2006
Citation
Masoud Alimardani, Ehsan Toyserkani; October 30–November 2, 2006. "On the 3D modeling of geometrical formation in laser solid freeform fabrication process." Proceedings of the ICALEO 2006: 25th International Congress on Laser Materials Processing and Laser Microfabrication. ICALEO 2006: 25th International Congress on Laser Materials Processing and Laser Microfabrication. Scottsdale, Arizona, USA. (pp. 2007). ASME. https://doi.org/10.2351/1.5060807
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