Enhancement of a quasi-analytical solution for modelling additive manufacturing processes
Tuesday, June 20, 2023, 11:00 AM - 11:20 AM
Max Bell Theatre
Shaun Cooke

Typically, numerical modelling methods such as finite element (FE) can provide accurate descriptions of laser or electron-beam melting processes, however the high computational costs at part-scale make them unsuitable for process modelling in additive manufacturing (AM). Alternative methods such as semi-analytical solutions based on a moving heat source have been applied to AM in the past, although the underlying assumptions are unrealistic. Additional heat transfer mechanisms such as radiation, temperature-dependent physical properties and latent heat are not considered in the semi-analytical approach but can have a significant effect on the thermal history. In this study, the error associated by each of these contributions are assessed against the conduction-only solution for a range of processing parameters. The semi-analytical model is then “enhanced” with FE results for single melt tracks to better encompass the heat transfer mechanisms in the AM process. The model is then validated experimentally with different beam trajectories using k-type thermocouples for selective laser melting on a solid Ti-6Al-4V substrate.

Moderated by: Steve Cockcroft / Farzaneh Farhang Mehr