Thermal behavior in single track during selective laser melting of AlSi10Mg powder

A three-dimensional model was developed to simulate the radiation heat transfer in the AlSi10Mg packed bed. The volume of fluid method (VOF) was used to capture the free surface during selective laser melting (SLM). A randomly packed powder bed was obtained using discrete element method (DEM) in Particle Flow Code (PFC). The proposed model has demonstrated a high potential to simulate the selective laser melting process (SLM) with high accuracy. In this paper, the effect of the laser scanning speed and laser power on the thermodynamic behavior of the molten pool was investigated numerically. The results show that the temperature gradient and the resultant surface tension gradient between the center and the edge of the molten pool increase with decreasing the scanning speed or increasing the laser power, thereby intensifying the Marangoni flow and attendant turbulence within the molten pool. However, at a relatively high scanning speed, a significant instability may be generated in the molten pool. The perturbation and instability in the molten pool during SLM may result in an irregular shaped track.