Scaling Effects in Laser-Based Additive Manufacturing Processes

摘要

Thermal modeling is used to address the control of melt pool size in laser-based additive powder fusion processes under steady state conditions. These processes use localized melting of metal powder to add features to metallic components during manufacture or repair. The problem of process size scale is considered, with the aim of applying knowledge developed at one size scale (e.g. the LENS™ process, using a 500 W laser) to similar processes operating at larger scales (e.g. a 3 kW system under development at South Dakota School of Mines and Technology). Results presented herein provide engineers with a means for easily predicting melt pool size for both of these processes over the full range of process variables. Results also demonstrate how process size scale affects the sensitivity of melt pool size to minor changes in process parameters. These issues are addressed via a process map approach developed by the authors and co-workers. This approach collapses results from a large number of simulations over the full range of practical process variables onto plots process engineers can easily use.