Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites
Abstract
:1. Introduction
2. Materials and SLM System
3. FE Modeling
3.1. Physical Description of Model
3.2. Initial Governing Equation
3.3. Heat-Source Model
3.4. Physical Properties of Materials
4. Results and Discussion
4.1. Numerical Validation and Melt-Pool Characterization
4.2. Temperature Distribution and Liquid Lifetime
4.3. Temperature Gradient
5. Conclusions
- (1)
- A 3D FE model for the SLM of Al2O3-reinforced and eutectic Al2O3-ZrO2-reinforced AISI 304 steel composite powders was developed and successfully employed to compare the effects of the reinforcing materials on the melt-pool behaviors.
- (2)
- The width and depth of the melt pool were larger for the eutectic-reinforced sample, which is mainly attributed to the reduction in the melting point and thermal conductivity in this sample. With the use of the eutectic Al2O3-ZrO2 instead of the Al2O3 reinforcing particle, the maximum temperature is increased due to the reduction in the thermal conductivity and latent heat of the mixture.
- (3)
- As the reinforcement content increases, the cooling rate decreases. The liquid lifetime of the melt pool has the effect on the melting behavior, rather than the cooling rate, and the liquid lifetime increases with the use of a eutectic ratio of Al2O3-ZrO2 reinforcement. An average and moderate condition for the liquid lifetime was identified to be 5 wt% for the eutectic mixture.
- (4)
- With the use of a eutectic Al2O3-ZrO2 reinforcing particle, the temperature gradient at the top surface reduces compared with the Al2O3-reinforced sample, due to a wider melt pool and a larger temperature distribution. This led to a narrower discrepancy between the micro-hardness of Al2O3-reinforced samples and the eutectic ratio of Al2O3-ZrO2-reinforced samples at the top layer, indicating an improvement in reinforcement particles’ distribution towards the surface in Al2O3-reinforced samples. The molten-pool behaviors and the thermal evolution of AISI 304 stainless-steel composites during the selective laser melting process will provide a deep understanding of the effect of reinforcing particles on the shape accuracies and properties of fabricated products.
Author Contributions
Funding
Conflicts of Interest
References
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Ex. No. | wt% of Al2O3 | wt% of Al2O3-ZrO2 | wt% of 304SS |
---|---|---|---|
1 | 0 | 0 | 100% |
2 | 3% | - | 97% |
3 | 5% | - | 95% |
4 | 7% | - | 93% |
5 | - | 3% | 97% |
6 | - | 5% | 95% |
7 | - | 7% | 93% |
Powder | R(i) | D(i) (m) | ϕ(i) | ρbulk (kg/m3) | ρpowder (kg/m3) | Apowder |
---|---|---|---|---|---|---|
AISI 304 | 0.46 | 20 × 10−6 | 0.25 | 7900 | 5861.8 | 0.604 |
Al2O3 | 0.79 | 3 × 10−6 | 0.65 | 3970 | 1580 | 0.173 |
ZrO2 | 0.82 | 1 × 10−6 | 0.21 | 6000 | 4740 | 0.266 |
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Abolhasani, D.; Seyedkashi, S.M.H.; Kang, N.; Kim, Y.J.; Woo, Y.Y.; Moon, Y.H. Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites. Metals 2019, 9, 876. https://doi.org/10.3390/met9080876
Abolhasani D, Seyedkashi SMH, Kang N, Kim YJ, Woo YY, Moon YH. Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites. Metals. 2019; 9(8):876. https://doi.org/10.3390/met9080876
Chicago/Turabian StyleAbolhasani, Daniyal, S. M. Hossein Seyedkashi, Namhyun Kang, Yang Jin Kim, Young Yun Woo, and Young Hoon Moon. 2019. "Analysis of Melt-Pool Behaviors during Selective Laser Melting of AISI 304 Stainless-Steel Composites" Metals 9, no. 8: 876. https://doi.org/10.3390/met9080876