Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion

Scheel, Pooriya; Wrobel, Rafal; Rheingans, Bastian; Mayer, Thomas; Leinenbach, Christian; Mazza, Edoardo; Hosseini, Ehsan

doi:10.1016/j.ijmecsci.2023.108583

Please use this identifier to cite or link to this item: https://doi.org/10.21256/zhaw-29349

Publication type:	Article in scientific journal
Type of review:	Peer review (publication)
Title:	Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion
Authors:	Scheel, Pooriya Wrobel, Rafal Rheingans, Bastian Mayer, Thomas Leinenbach, Christian Mazza, Edoardo Hosseini, Ehsan
et. al:	No
DOI:	10.1016/j.ijmecsci.2023.108583 10.21256/zhaw-29349
Published in:	International Journal of Mechanical Sciences
Volume(Issue):	260
Issue:	108583
Issue Date:	2023
Publisher / Ed. Institution:	Elsevier
ISSN:	0020-7403
Language:	English
Subjects:	Laser powder bed fusion; Finite element thermal analysis; In-situ measurement; Multiscale modelling; Computational efficiency
Subject (DDC):	670: Manufacturing
Abstract:	In laser based powder-bed fusion of metals (PBF-LB/M), parts are fabricated by melting layers of powder using a high-intensity laser beam. During this process, the material is exposed to rapid cooling rates and intense thermal gradients, which are the underlying causes of residual stress formation and development of a unique microstructure in these components. Therefore, understanding the heat transfer phenomenon and reliably representing exposed temperature profiles in simulation frameworks are prerequisites for studying the microstructure and residual stress development during the PBF-LB/M process. This work employs a combination of experimental measurements and model development to study this phenomenon. Thermal properties of Hastelloy X were measured in the as-deposited state and used to setup finite element (FE) thermal simulations of the PBF-LB/M process. In addition, in-situ temperature evolutions near the laser tracks were measured by instrumenting thin-wall structures with K-type thermocouples in a two-stage fabrication process. The gathered data was used to calibrate uncertain modelling parameters, and ultimately, the simulation framework could closely represent the measured temperature histories. To address the high computational cost of FE thermal simulations, an adaptive-local/global multiscale modelling approach was proposed, which substantially reduced computation times without compromising the accuracy of the results. The modelling files and scripts are available in github.
URI:	https://digitalcollection.zhaw.ch/handle/11475/29349
Related research data:	https://github.com/HighTempIntegrity/Ghanbari_Multiscale2023
Fulltext version:	Published version
License (according to publishing contract):	CC BY 4.0: Attribution 4.0 International
Departement:	School of Engineering
Organisational Unit:	Institute of Mechanical Systems (IMES)
Appears in collections:	Publikationen School of Engineering

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Scheel, P., Wrobel, R., Rheingans, B., Mayer, T., Leinenbach, C., Mazza, E., & Hosseini, E. (2023). Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion. International Journal of Mechanical Sciences, 260(108583). https://doi.org/10.1016/j.ijmecsci.2023.108583

Scheel, P. et al. (2023) ‘Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion’, International Journal of Mechanical Sciences, 260(108583). Available at: https://doi.org/10.1016/j.ijmecsci.2023.108583.

P. Scheel et al., “Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion,” International Journal of Mechanical Sciences, vol. 260, no. 108583, 2023, doi: 10.1016/j.ijmecsci.2023.108583.

SCHEEL, Pooriya, Rafal WROBEL, Bastian RHEINGANS, Thomas MAYER, Christian LEINENBACH, Edoardo MAZZA und Ehsan HOSSEINI, 2023. Advancing efficiency and reliability in thermal analysis of laser powder-bed fusion. International Journal of Mechanical Sciences. 2023. Bd. 260, Nr. 108583. DOI 10.1016/j.ijmecsci.2023.108583

Scheel, Pooriya, Rafal Wrobel, Bastian Rheingans, Thomas Mayer, Christian Leinenbach, Edoardo Mazza, and Ehsan Hosseini. 2023. “Advancing Efficiency and Reliability in Thermal Analysis of Laser Powder-Bed Fusion.” International Journal of Mechanical Sciences 260 (108583). https://doi.org/10.1016/j.ijmecsci.2023.108583.

Scheel, Pooriya, et al. “Advancing Efficiency and Reliability in Thermal Analysis of Laser Powder-Bed Fusion.” International Journal of Mechanical Sciences, vol. 260, no. 108583, 2023, https://doi.org/10.1016/j.ijmecsci.2023.108583.