Multi-scale modeling of selective electron beam melting of Ti6Al4V titanium alloy

Trong Nhan Le, Yu Lung Lo, Hong Chuong Tran

Research output: Contribution to journalArticle

Abstract

Selective electron beam melting (SEBM) is one of the most promising powder-based metal additive manufacturing (AM) technologies. However, controlling the SEBM process parameters in such a way as to maximize the quality of the fabricated components represents a significant challenge. Accordingly, taking Ti6Al4V titanium alloy for illustration purposes, the present study constructs a novel multi-scale modeling framework to examine the effects of three SEBM process parameters (namely the beam current, the beam diameter, and the scanning speed) on the dimensions and temperature distribution of the melt pool. In microscale, an effective model considering the interactions between the electron beam and the Ti6Al4V atoms was constructed based on the Monte Carlo ray-tracing simulations, and the electron beam total absorption of Ti6Al4V material as a function of incidence angle was obtained. In mesoscopic level, in order to take the absorption property of the porous structure of the powder layer into account, absorptivity profile along the depth of the powder bed was calculated by utilizing the absorptivity of Ti6Al4V for various incidence angles and the 3-D powder bed model. It is found that the total laser absorptivity of the Ti6Al4V powder bed is around 12% higher than that of the bulk material of Ti6Al4V due to the multiple reflection of electron beam inside the powder layer. Finally, three-dimensional finite element heat transfer simulations are performed using the proposed volumetric heat source to predict the melt pool geometry and thermal distribution during the SEBM process. It is shown that the simulation results are in good agreements with the experimental results reported in the literature.

Original languageEnglish
Pages (from-to)545-563
Number of pages19
JournalInternational Journal of Advanced Manufacturing Technology
Volume105
Issue number1-4
DOIs
Publication statusPublished - 2019 Nov 1

Fingerprint

Electron beam melting
Titanium alloys
Powders
Electron beams
3D printers
Beam plasma interactions
Ray tracing
Temperature distribution
Heat transfer
Scanning
Atoms
Geometry
Lasers
Metals

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

Cite this

@article{7bed1793587143a3b9988e2eca53336c,
title = "Multi-scale modeling of selective electron beam melting of Ti6Al4V titanium alloy",
abstract = "Selective electron beam melting (SEBM) is one of the most promising powder-based metal additive manufacturing (AM) technologies. However, controlling the SEBM process parameters in such a way as to maximize the quality of the fabricated components represents a significant challenge. Accordingly, taking Ti6Al4V titanium alloy for illustration purposes, the present study constructs a novel multi-scale modeling framework to examine the effects of three SEBM process parameters (namely the beam current, the beam diameter, and the scanning speed) on the dimensions and temperature distribution of the melt pool. In microscale, an effective model considering the interactions between the electron beam and the Ti6Al4V atoms was constructed based on the Monte Carlo ray-tracing simulations, and the electron beam total absorption of Ti6Al4V material as a function of incidence angle was obtained. In mesoscopic level, in order to take the absorption property of the porous structure of the powder layer into account, absorptivity profile along the depth of the powder bed was calculated by utilizing the absorptivity of Ti6Al4V for various incidence angles and the 3-D powder bed model. It is found that the total laser absorptivity of the Ti6Al4V powder bed is around 12{\%} higher than that of the bulk material of Ti6Al4V due to the multiple reflection of electron beam inside the powder layer. Finally, three-dimensional finite element heat transfer simulations are performed using the proposed volumetric heat source to predict the melt pool geometry and thermal distribution during the SEBM process. It is shown that the simulation results are in good agreements with the experimental results reported in the literature.",
author = "Le, {Trong Nhan} and Lo, {Yu Lung} and Tran, {Hong Chuong}",
year = "2019",
month = "11",
day = "1",
doi = "10.1007/s00170-019-04188-x",
language = "English",
volume = "105",
pages = "545--563",
journal = "International Journal of Advanced Manufacturing Technology",
issn = "0268-3768",
publisher = "Springer London",
number = "1-4",

}

Multi-scale modeling of selective electron beam melting of Ti6Al4V titanium alloy. / Le, Trong Nhan; Lo, Yu Lung; Tran, Hong Chuong.

In: International Journal of Advanced Manufacturing Technology, Vol. 105, No. 1-4, 01.11.2019, p. 545-563.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Multi-scale modeling of selective electron beam melting of Ti6Al4V titanium alloy

AU - Le, Trong Nhan

AU - Lo, Yu Lung

AU - Tran, Hong Chuong

PY - 2019/11/1

Y1 - 2019/11/1

N2 - Selective electron beam melting (SEBM) is one of the most promising powder-based metal additive manufacturing (AM) technologies. However, controlling the SEBM process parameters in such a way as to maximize the quality of the fabricated components represents a significant challenge. Accordingly, taking Ti6Al4V titanium alloy for illustration purposes, the present study constructs a novel multi-scale modeling framework to examine the effects of three SEBM process parameters (namely the beam current, the beam diameter, and the scanning speed) on the dimensions and temperature distribution of the melt pool. In microscale, an effective model considering the interactions between the electron beam and the Ti6Al4V atoms was constructed based on the Monte Carlo ray-tracing simulations, and the electron beam total absorption of Ti6Al4V material as a function of incidence angle was obtained. In mesoscopic level, in order to take the absorption property of the porous structure of the powder layer into account, absorptivity profile along the depth of the powder bed was calculated by utilizing the absorptivity of Ti6Al4V for various incidence angles and the 3-D powder bed model. It is found that the total laser absorptivity of the Ti6Al4V powder bed is around 12% higher than that of the bulk material of Ti6Al4V due to the multiple reflection of electron beam inside the powder layer. Finally, three-dimensional finite element heat transfer simulations are performed using the proposed volumetric heat source to predict the melt pool geometry and thermal distribution during the SEBM process. It is shown that the simulation results are in good agreements with the experimental results reported in the literature.

AB - Selective electron beam melting (SEBM) is one of the most promising powder-based metal additive manufacturing (AM) technologies. However, controlling the SEBM process parameters in such a way as to maximize the quality of the fabricated components represents a significant challenge. Accordingly, taking Ti6Al4V titanium alloy for illustration purposes, the present study constructs a novel multi-scale modeling framework to examine the effects of three SEBM process parameters (namely the beam current, the beam diameter, and the scanning speed) on the dimensions and temperature distribution of the melt pool. In microscale, an effective model considering the interactions between the electron beam and the Ti6Al4V atoms was constructed based on the Monte Carlo ray-tracing simulations, and the electron beam total absorption of Ti6Al4V material as a function of incidence angle was obtained. In mesoscopic level, in order to take the absorption property of the porous structure of the powder layer into account, absorptivity profile along the depth of the powder bed was calculated by utilizing the absorptivity of Ti6Al4V for various incidence angles and the 3-D powder bed model. It is found that the total laser absorptivity of the Ti6Al4V powder bed is around 12% higher than that of the bulk material of Ti6Al4V due to the multiple reflection of electron beam inside the powder layer. Finally, three-dimensional finite element heat transfer simulations are performed using the proposed volumetric heat source to predict the melt pool geometry and thermal distribution during the SEBM process. It is shown that the simulation results are in good agreements with the experimental results reported in the literature.

UR - http://www.scopus.com/inward/record.url?scp=85070738119&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=85070738119&partnerID=8YFLogxK

U2 - 10.1007/s00170-019-04188-x

DO - 10.1007/s00170-019-04188-x

M3 - Article

AN - SCOPUS:85070738119

VL - 105

SP - 545

EP - 563

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

SN - 0268-3768

IS - 1-4

ER -