Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modelling
The laser powder bed fusion (LPBF) process encompasses interactions between different material states, including melt, gas, and powder. While observational techniques can capture specific states, they cannot be combined to produce a comprehensive monitoring how they are mutually interacted. Thus, an...
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2024.2446619 |
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| author | Weihao Yuan Hui Chen Siyuan Ruan Rocco Lupoi Shaocong Qin Enyu Guo Jianfeng Wang Shuo Yin |
| author_facet | Weihao Yuan Hui Chen Siyuan Ruan Rocco Lupoi Shaocong Qin Enyu Guo Jianfeng Wang Shuo Yin |
| author_sort | Weihao Yuan |
| collection | DOAJ |
| description | The laser powder bed fusion (LPBF) process encompasses interactions between different material states, including melt, gas, and powder. While observational techniques can capture specific states, they cannot be combined to produce a comprehensive monitoring how they are mutually interacted. Thus, an integrated modelling approach is a crucial solution for revealing their interactions. This study investigates melt-gas-powder dynamics under varying laser scan speeds through a coupled CFD-DEM multiphase model. Findings reveal that metal vapour consistently transitions from an initialisation phase to a processing phase, exhibiting consistent behaviour in the former but varied responses in the latter. A relationship is identified between scan speed and vapour flow angle (VFA), with higher speeds broadening the VFA. Significantly, three oscillatory behaviours are observed: first, the oscillation of locally intensified pressure (LIP) sites on keyhole walls, where vapour ejection modes shift and may become periodic at intermediate scan speeds; second, the oscillation of two induced argon vortex flows with opposite swirling directions; and third, a simultaneously induced varying drag force on powder spatter. These oscillations clarify various spatter mechanisms, offer insights for process optimisation, and suggest implications for process stability. The study also proposes future research directions to further elucidate these mechanisms. |
| format | Article |
| id | doaj-art-f7f854763f0d4d678bdd943bc9a0a54d |
| institution | Kabale University |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-f7f854763f0d4d678bdd943bc9a0a54d2025-01-15T18:45:55ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2024.2446619Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modellingWeihao Yuan0Hui Chen1Siyuan Ruan2Rocco Lupoi3Shaocong Qin4Enyu Guo5Jianfeng Wang6Shuo Yin7Department of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, The University of Dublin, Dublin 2, IrelandState Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, People’s Republic of ChinaDepartment of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, The University of Dublin, Dublin 2, IrelandDepartment of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, The University of Dublin, Dublin 2, IrelandDepartment of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, The University of Dublin, Dublin 2, IrelandKey Laboratory of Solidification Control and Digital Preparation Technology, School of Materials Science and Engineering, Dalian University of Technology, Dalian, People’s Republic of ChinaDepartment of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, The University of Dublin, Dublin 2, IrelandDepartment of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, The University of Dublin, Dublin 2, IrelandThe laser powder bed fusion (LPBF) process encompasses interactions between different material states, including melt, gas, and powder. While observational techniques can capture specific states, they cannot be combined to produce a comprehensive monitoring how they are mutually interacted. Thus, an integrated modelling approach is a crucial solution for revealing their interactions. This study investigates melt-gas-powder dynamics under varying laser scan speeds through a coupled CFD-DEM multiphase model. Findings reveal that metal vapour consistently transitions from an initialisation phase to a processing phase, exhibiting consistent behaviour in the former but varied responses in the latter. A relationship is identified between scan speed and vapour flow angle (VFA), with higher speeds broadening the VFA. Significantly, three oscillatory behaviours are observed: first, the oscillation of locally intensified pressure (LIP) sites on keyhole walls, where vapour ejection modes shift and may become periodic at intermediate scan speeds; second, the oscillation of two induced argon vortex flows with opposite swirling directions; and third, a simultaneously induced varying drag force on powder spatter. These oscillations clarify various spatter mechanisms, offer insights for process optimisation, and suggest implications for process stability. The study also proposes future research directions to further elucidate these mechanisms.https://www.tandfonline.com/doi/10.1080/17452759.2024.2446619Coupled CFD-DEM modelvapour phaselocally intensified pressurevortex flowdrage force |
| spellingShingle | Weihao Yuan Hui Chen Siyuan Ruan Rocco Lupoi Shaocong Qin Enyu Guo Jianfeng Wang Shuo Yin Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modelling Virtual and Physical Prototyping Coupled CFD-DEM model vapour phase locally intensified pressure vortex flow drage force |
| title | Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modelling |
| title_full | Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modelling |
| title_fullStr | Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modelling |
| title_full_unstemmed | Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modelling |
| title_short | Oscillatory nature in melt-gas-powder interactions during laser powder bed fusion process revealed by CFD-DEM coupled modelling |
| title_sort | oscillatory nature in melt gas powder interactions during laser powder bed fusion process revealed by cfd dem coupled modelling |
| topic | Coupled CFD-DEM model vapour phase locally intensified pressure vortex flow drage force |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2024.2446619 |
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