دانلود رایگان مقاله انگلیسی مدل تحلیلی جامع برای تولید افزایشی پودر تغذیه لیزری - نشریه الزویر

abstract

This paper addresses a comprehensive analytical model for the laser powder-fed additive manufacturing (LPF-AM) process, also known as directed energy deposition AM. The model analytically couples the moving laser beam with Gaussian energy distribution, the powder stream and the semi-infinite substrate together, while considering the attenuated laser power intensity distribution, the heated powder spatial distribution and the melt pool 3D shape with its boundary variation. The particles concentration on transverse plane is modeled with Gaussian distribution based on optical measurement. The model can effectively be used for process development/optimization and controller design, while predicting adequate clad geometry as well as the catchment efficiency rapidly. Experimental validation through the deposition of Inconel 625 proves the model can accurately predict the clad geometry and catchment efficiency in the range of specific energy that is corresponding to high clad quality (maximum percentage difference is 6.2% for clad width, 7.8% for clad height and 6.8% for catchment efficiency).

6. Conclusion

An analytical model of LPF-AM was developed in this paper. The attenuated laser power and heated powder stream flow were coupled together with Gaussian intensity distribution. By substituting the coupled energy into the Rosenthal’s 3D moving heat source model, and combining with the calculated clad height, the 3D melt pool geometry was built with consideration of the Brewster effect. A solution to calculate the process catchment efficiency was developed with considering the powder concentration distribution, the melt pool inclination and boundary variation. Experimental validation using Inconel 625 shows the model can accurately predict the clad geometry as well as the process catchment efficiency in the case of high clad quality expected. The built analytical model can provide a proper platform for the design of controllers for LPF-AM using high speed hardware.