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HEAT TRANSFER, PHASE CHANGE AND COALESCENCE OF PARTICLES DURING SELECTIVE LASER SINTERING OF METAL POWDERS

Ram Dayal
Center of Smart Interfaces, Technische Universität Darmstadt, Petersenstr. 3264287 Germany ; Institute of Technical Thermodynamics, Technische Universitat Darmstadt, Petersenstr. 17, 64287 Germany; School of Automobile, Mechanical and Mechatronics Engineering, Manipal University Jaipur, India

Tatiana Gambaryan-Roisman
Institute of Technical Thermodynamics and Center of Smart Interfaces, Technische Universitat Darmstadt, Alarich-Weiss-Str. 10, 64287, Darmstadt, Germany

Eberhard Abele
Center of Smart Interfaces, Technische Universität Darmstadt; Institute of Production Management, Technology and Machine Tools, Technische Universität Darmstadt, 64287 Germany

Abstract

Flow and heat transfer during selective laser sintering of metal powder is investigated numerically. Heat transfer, melting and resolidification, which are induced by laser irradiance and coupled with coalescence of partially melted particles, are dominant processes governing laser sintering of metal powders. The present model accounts for phase change during the laser heating and cooling cycle and subsequent melt flow due to surface tension forces. The study is aimed to gain understanding of mechanisms governing microstructure formation during selective laser sintering. A two-dimensional boundary element (BEM) model is used to solve the governing equations. The solid-liquid interface during phase change is tracked using Stefan condition at the interface. The liquid melt formed due to melting is assumed to be viscous. The influence of process parameters on temperature field evolution, shape evolution and densification rate is quantified and discussed.

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