Numerical simulation of melt pool size and flow evolution for laser powder bed fusion of powder grade Ti6Al4V.

The study of molten pool characteristics is a powerful means of determining the quality of laser additive manufacturing forming. In this paper, a three-dimensional transient thermal flow field numerical model of Ti6Al4V powder processed by LPBF is developed based on FLOW-3D software, and the dynamic evolution of the molten pool with fixed process parameters is quantitatively described using dimensionless numbers in computational fluid dynamics. It is shown that the main heat transfer mode of the molten pool is thermal convection; the evaporative back sitting pressure, surface tension and Marangoni shear force are the main driving forces for the evolution of the molten pool. Furthermore, the influence of key process parameters on the heat flow field of the molten pool was analyzed. When the laser power was 300 W, the depression depth and molten pool depth caused by the recoil pressure were significantly larger, and the isothermal density of the solidification region was more intensive; when the scanning speed was increased from 0.4 m/s to 0.8 m/s, the molten pool length was reduced from 524 μm to 410 μm, and the line energy density was reduced making the amount of melted powder decrease. The wettability and fluidity of the molten state metal becomes worse; when the scanning interval increases to 120 μm, a large number of incompletely melted powder tracks cannot lap correctly at the midline of the double track. The results of the above simulations achieve a high degree of agreement with the surface quality of the specimens during the experiments, which provides guidance for quantitative analysis of molten pool evolution and prediction of Ti6Al4V forming quality. • Based on the Discrete Element Method, a Ti6Al4V powder-scale LPBF thermal flow field model was established. • The influence of key process parameters on surface forming quality was studied. • The experiment and simulation agree well, providing guidance for optimizing the forming of Ti6Al4V. [ABSTRACT FROM AUTHOR]