SAMPE Journal - November/December 2019 - 28
FEATURE / ADDITIVE MANUFACTURED TOOLSET PARTS
or a heat flux to the liquefier (or constant wall
temperature) during FFF and FDM AM processes.
This multi-physics multi-phase (solid, powder
and liquid) module aims to compensate for the
systematic physical property variabilities of
the powder bed layer (e.g. density and volume
changes, Volume of Solid (VOS), void formation,
shrinkage, liquid formation and movement due
to melting) and to determine process parameters
for the subsequent layers to correct the defects in
previous layers.
In general, the thermal management model
and the algorithm has the following predictive
capabilities:
I. Real-time calculation/prediction of micro- and
macro-scale thermal history including heating,
melting, melt-superheating, superheat-cooling,
solidification/sintering, and cooling periods
(Figure 11).
Figure 14. Thermal Management (TMg) prediction of ) Dynamic Void Map per layer (p, v, void)
showing low and high void content.
II. To calculate the dynamic evolution of HAZ as
well as meltpool size and shape (length, width,
and depth) during printing process of different
AM processes such as LPBF, DED, SLM, FFF, FDM,
BAAM and etc. (Figure 12).
III. Prediction of Transient Material States (i.e.
transient density, volume of solid (VOS), and
void volume ratios) which is obtained by taking
temperature history, temperature dependent
density function, material phase (powder, solid,
and liquid) and meltpool shape and size into
account. This predictive tool can be used for
further analysis to predict roughness and residual
stress, eventually (Figure 13).
IV. Prediction of zones of stabilities
instabilities in 3DP AM processes.
a) Meltpool Depth: ZOM vs. Test
and
V. Developing of dynamic Process MAP, based on
different print parameters (such as speed, power,
layer thickness, hatch spacing, etc. vs. maximum
temperature), to predict the optimum as well as
the safe/stable and unsafe/unstable printing
parameters and regions (Figure 14).
Validated Case Studies
The ZOM thermal model prediction was validated
against various experiments for different materials
including: LPBF of Ti-6Al-4V metal-powder with
the solid base plate in which the dynamic evolution
of melt pool was validated against test with respect
to melt pool size (depth and width). The leaser was
on for 1000 μs assuming static laser condition (laser
stationary case). Two different power cases (340 W
and 520 W) were validated against the dynamic
X-ray test data from Argonne National Lab (Zhao et
28
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SAMPE JOURNAL
|
b) Meltpool Depth/Width: ZOM vs. Test
Figure 15. Prediction/validation of ZOM vs. Argonne National Lab test data
for Titanium.
N OV E M B E R / D E C E M B E R 2 0 1 9
w w w. s a m p e . o r g
http://www.sampe.org
SAMPE Journal - November/December 2019
Table of Contents for the Digital Edition of SAMPE Journal - November/December 2019
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SAMPE Journal - November/December 2019 - Table of contents
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