A hybrid mesoscale-continuum approach to understand and predict melting kinetics of Al powders during laser processing

Laser interaction with metallic powders during additive manufacturing (AM) leads to fast heating and cooling rates that can affect the quality of the final products due to the formation of defects. One of the first steps towards predicting microstructures generated during AM, therefore, requires an accurate understanding of the laser energy deposition mechanisms that determine the melting kinetics at the level of individual powders. The critical challenge, however, is the availability of computational methods that can model the laser energy absorption, heat transfer, and the related microstructure evolution in individual metal powders at the length and time scales of AM. This manuscript demonstrates the capability of a novel scale-bridging methodology that combines the mesoscale quasi-coarse-grained dynamics (QCGD) simulations with a continuum two-temperature model (TTM) to account for the atomistic mechanisms of laser energy deposition and microstructure evolution and predict the kinetics of melting of individual powders at the experimental time and length scales. The scale-bridging capability of the hybrid QCGD-TTM simulations is demonstrated here by investigating the laser-induced microstructure evolution in aluminum powders with various sizes ranging from 200 nm to 20 µ m. The analysis of the evolution of temperature, pressure, phase fraction, and melt fronts suggests the melting mechanism is heterogeneous due to the interaction with a laser, and the melting time is observed to decrease exponentially as the laser intensity increases. The solid–liquid interface velocity can be quantified to identify correlations with interface temperatures, and the predicted values satisfy the theoretically reported limits of crystal stability of metals against homogeneous melting. In addition, the pre-melting is found at the grain boundaries of 20 µ m polycrystalline aluminum powder, while a minute contribution to melting is observed. This manuscript demonstrates the capability of the QCGD-TTM method to capture laser-powder interaction and allow the investigation of the kinetics of laser melting.