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Finite element modeling of melt pool dynamics in laser powder bed fusion of 316L stainless steel

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Abstract

In laser powder bed fusion (LPBF), the stability of melt pool dynamics determines the overall quality of a manufactured component. In this work, a numerical model of the LPBF process was developed in order to study and fully understand the behavior of the melt pool dynamics. The numerical model takes into account most of the manufacturing parameters, thermophysical properties, an enhanced thermal conductivity approach, and a volumetric heat source in order to precisely simulate LPBF. This research assumes that the energy emitted by the laser interacts with the metal powder with an absorptivity gradient through the layer thickness in order to calculate the thermal history of the process and the evolution of the melt pool dimensions. The obtained results determined that melt pool dimensions follow a thermal pattern, which is caused by the laser scanning strategy of the LPBF process. A new effective width criterion was proposed in the present research in order to accurately relate both calculated and measured dimensions of the melt pool, reducing the relative error of the model and obtaining data scattering with a standard deviation of ± 7.21 µm and a relative error of 2.92%.

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Availability of data and material

The data presented in this study are available upon request to the corresponding author. All the data is presented within the article.

Code availability

The code used to obtain the FEM results in this study is available upon request to the corresponding author.

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Funding

The authors received financial support provided by the Institutional Fund for Regional Scientific, Technological and Innovation Development (FORDECyT) of the National Council of Science and Technology (CONACyT) of Mexico, through the project “Aeronautical Strengthening in Mexico’s North East Region.”

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Authors and Affiliations

  1. Universidad Autónoma de Nuevo León, Facultad de Ingeniería Mecánica Y Eléctrica, Centro de Investigación E Innovación en Ingeniería Aeronáutica (CIIIA), Carretera a Salinas Victoria km 2.3, Apodaca, 66600, Mexico

    Juan Trejos-Taborda, Luis Reyes-Osorio, Carlos Garza & Patricia del Carmen Zambrano-Robledo

  2. Tecnologico de Monterrey, Av. Eugenio Garza Sada 2501 Sur, Monterrey, 64849, Mexico

    Omar Lopez-Botello

  3. Laboratorio Nacional de Manufactura Aditiva Y Digital (MADiT), Mexico City, 04510, Mexico

    Juan Trejos-Taborda, Luis Reyes-Osorio, Patricia del Carmen Zambrano-Robledo & Omar Lopez-Botello

  4. Consejo Nacional de Ciencia Y Tecnología (CONACyT), Av. Insurgentes Sur 1582, Mexico City, 03940, Mexico

    Carlos Garza

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  1. Juan Trejos-Taborda
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  2. Luis Reyes-Osorio
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  3. Carlos Garza
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  4. Patricia del Carmen Zambrano-Robledo
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  5. Omar Lopez-Botello
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Contributions

Methodology — JTT, LRO, CG, OLB; conceptualization — OLB; validation — JTT; formal analysis — JTT; investigation — JTT; writing original draft — JTT; writing review and editing — LRO, CG, PZR, OLB; visualization — JTT, OLB; supervision — PZR, OLB; funding — PZR.

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Correspondence to Omar Lopez-Botello.

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Trejos-Taborda, J., Reyes-Osorio, L., Garza, C. et al. Finite element modeling of melt pool dynamics in laser powder bed fusion of 316L stainless steel. Int J Adv Manuf Technol 120, 3947–3961 (2022). https://doi.org/10.1007/s00170-022-09029-y

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