Skip to main content
Top
Published in: Journal of Materials Science 8/2017

01-09-2016 | IIB 2016

Phase-field model of interface migration and powder consolidation in additive manufacturing of metals

Authors: M. D. Krivilyov, S. Dj. Mesarovic, D. P. Sekulic

Published in: Journal of Materials Science | Issue 8/2017

Log in

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

Consolidation phenomena are of fundamental importance for additive manufacturing since the quality of metal parts produced by selective laser melting (SLM) is greatly dependent on residual porosity. The most recent studies use the lattice Boltzmann method (LBM) to analyze conjugated multiphase flow, heat transport, and phase transitions in the molten zone. A phase-field approach suggested in this paper retains all advantages of LBM and provides an alternative tool for theoretical analysis of SLM. In case of consolidation of composite powders where wetting phenomena are crucial at the matrix-inclusion interfaces, the phase-field method is more suitable. In this paper, the problem of metallic powder consolidation is numerically studied and the dynamics of pore and gas bubbles evolution in the molten zone is described. A two-step mechanism of consolidation is proposed which differs from a single-step mechanism typical for additive manufacturing of polymer powders. The consolidation time for different particle orderings is studied and an algorithm for the parameter selection in the widely used viscoplastic model is derived.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Literature
1.
go back to reference Bourell DL, Marcus HL, Barlow JW, Beaman JJ (1992) Selective laser sintering of metals and ceramics. Int J Powder Metall 28:369–381 Bourell DL, Marcus HL, Barlow JW, Beaman JJ (1992) Selective laser sintering of metals and ceramics. Int J Powder Metall 28:369–381
2.
go back to reference Kruth JP (1991) Material incress manufacturing by rapid prototyping techniques. CIRP Ann Manuf Technol 40:603–614CrossRef Kruth JP (1991) Material incress manufacturing by rapid prototyping techniques. CIRP Ann Manuf Technol 40:603–614CrossRef
4.
go back to reference Wauthle R, van der Stok J, Yavari SA, Van Humbeeck J, Kruth J-P et al (2015) Additively manufactured porous tantalum implants. Acta Biomater 14:217–225CrossRef Wauthle R, van der Stok J, Yavari SA, Van Humbeeck J, Kruth J-P et al (2015) Additively manufactured porous tantalum implants. Acta Biomater 14:217–225CrossRef
5.
go back to reference Kruth J-P, Leu MC, Nakagawa T (1998) Progress in additive manufacturing and rapid prototyping. CIRP Ann Manuf Technol 47:525–540CrossRef Kruth J-P, Leu MC, Nakagawa T (1998) Progress in additive manufacturing and rapid prototyping. CIRP Ann Manuf Technol 47:525–540CrossRef
6.
go back to reference Gao W, Zhang Y, Ramanujan D, Ramani K, Chen Y, Williams CB, Wang CCL, Shin YC, Zhang S, Zavattieri PD (2015) The status, challenges, and future of additive manufacturing in engineering. Comput Aided Des 69:65–89CrossRef Gao W, Zhang Y, Ramanujan D, Ramani K, Chen Y, Williams CB, Wang CCL, Shin YC, Zhang S, Zavattieri PD (2015) The status, challenges, and future of additive manufacturing in engineering. Comput Aided Des 69:65–89CrossRef
7.
go back to reference Kruth J-P, Levy G, Klocke F, Childs THC (2007) Consolidation phenomena in laser and powder-bed based layered manufacturing. CIRP Ann Manuf Technol 56:730–759CrossRef Kruth J-P, Levy G, Klocke F, Childs THC (2007) Consolidation phenomena in laser and powder-bed based layered manufacturing. CIRP Ann Manuf Technol 56:730–759CrossRef
8.
go back to reference Khairallah SA, Anderson AT, Rubenchik A, King WE (2016) Laser powder-bed fusion additive manufacturing: physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones. Acta Mater 108:36–45CrossRef Khairallah SA, Anderson AT, Rubenchik A, King WE (2016) Laser powder-bed fusion additive manufacturing: physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones. Acta Mater 108:36–45CrossRef
9.
go back to reference Khairallah SA, Anderson A (2014) Mesoscopic simulation model of selective laser melting of stainless steel powder. J Mater Process Techol 214:2627–2636CrossRef Khairallah SA, Anderson A (2014) Mesoscopic simulation model of selective laser melting of stainless steel powder. J Mater Process Techol 214:2627–2636CrossRef
10.
go back to reference Provatas N, Elder K (2010) Phase-field methods in materials science and engineering. Wiley, VCHCrossRef Provatas N, Elder K (2010) Phase-field methods in materials science and engineering. Wiley, VCHCrossRef
11.
go back to reference Warren JA, Boettinger WJ (1995) Prediction of dendritic growth and microsegregation patterns in a binary alloy using the phase-field method. Acta Metall Mater 43:689–703CrossRef Warren JA, Boettinger WJ (1995) Prediction of dendritic growth and microsegregation patterns in a binary alloy using the phase-field method. Acta Metall Mater 43:689–703CrossRef
12.
go back to reference Danilov D, Nestler B (2005) Phase-field simulations of solidification in binary and ternary systems using a finite element method. J Cryst Growth 275:e177–e182CrossRef Danilov D, Nestler B (2005) Phase-field simulations of solidification in binary and ternary systems using a finite element method. J Cryst Growth 275:e177–e182CrossRef
13.
go back to reference Chen L-Q (1994) Computer simulation of spinodal decomposition in ternary systems. Acta Metall Mater 42:3503–3513CrossRef Chen L-Q (1994) Computer simulation of spinodal decomposition in ternary systems. Acta Metall Mater 42:3503–3513CrossRef
14.
go back to reference Elder KR, Grant M (2004) Modeling elastic and plastic deformations in nonequilibrium processing using phase field crystals. Phys Rev E 70:051605CrossRef Elder KR, Grant M (2004) Modeling elastic and plastic deformations in nonequilibrium processing using phase field crystals. Phys Rev E 70:051605CrossRef
15.
go back to reference Asle Zaeem M, Mesarovic SDj (2010) Morphological instabilities in multilayer thin films. Comput Mater Sci 50:1030–1036CrossRef Asle Zaeem M, Mesarovic SDj (2010) Morphological instabilities in multilayer thin films. Comput Mater Sci 50:1030–1036CrossRef
16.
go back to reference Anderson DM, McFadden GB, Wheeler AA (1998) Diffuse-interface methods in fluid mechanics. Annu Rev Fluid Mech 30:139–165CrossRef Anderson DM, McFadden GB, Wheeler AA (1998) Diffuse-interface methods in fluid mechanics. Annu Rev Fluid Mech 30:139–165CrossRef
17.
18.
go back to reference Dehsara M, Mesarovic SDj, Fu H, Sekulic D.P., Krivilyov M (2017) Phase field models for capillary flows. Int J Multiph Flow (submitted) Dehsara M, Mesarovic SDj, Fu H, Sekulic D.P., Krivilyov M (2017) Phase field models for capillary flows. Int J Multiph Flow (submitted)
19.
go back to reference Cahn JW, Hilliard JE (1958) Free energy of a nonuniform system. Part I. Interfacial free energy. J Chem Phys 28:258–267CrossRef Cahn JW, Hilliard JE (1958) Free energy of a nonuniform system. Part I. Interfacial free energy. J Chem Phys 28:258–267CrossRef
20.
go back to reference Gordeev G, Krivilyov M, Ankudinov V, Kharanzhevskiy E, Bogdanov A (2016) Computer simulation of selective laser melting of carbonyl iron powder. In: Proceedings of the 2nd international conference on additive manufacturing, Moscow, VIAM, March 16th 2016, 15 p Gordeev G, Krivilyov M, Ankudinov V, Kharanzhevskiy E, Bogdanov A (2016) Computer simulation of selective laser melting of carbonyl iron powder. In: Proceedings of the 2nd international conference on additive manufacturing, Moscow, VIAM, March 16th 2016, 15 p
21.
go back to reference Bird RB, Stewart WE, Lightfoot EN (2007) Transport phenomena, 2nd edn. Wiley, New York Bird RB, Stewart WE, Lightfoot EN (2007) Transport phenomena, 2nd edn. Wiley, New York
22.
go back to reference Kharanzhevskiy EV, Krivilyov MD (2011) Laser sintering of Fe–Ni nanocomposites. Phys Met Metallogr 111:53–61CrossRef Kharanzhevskiy EV, Krivilyov MD (2011) Laser sintering of Fe–Ni nanocomposites. Phys Met Metallogr 111:53–61CrossRef
Metadata
Title
Phase-field model of interface migration and powder consolidation in additive manufacturing of metals
Authors
M. D. Krivilyov
S. Dj. Mesarovic
D. P. Sekulic
Publication date
01-09-2016
Publisher
Springer US
Published in
Journal of Materials Science / Issue 8/2017
Print ISSN: 0022-2461
Electronic ISSN: 1573-4803
DOI
https://doi.org/10.1007/s10853-016-0311-z

Other articles of this Issue 8/2017

Journal of Materials Science 8/2017 Go to the issue

Premium Partners