Comptes Rendus
no. 11
Computational methods in welding and additive manufacturing/Simulation numérique des procédés de soudage et de fabrication additive
Computational modeling of heat transfer and sintering behavior during direct metal laser sintering of AlSi10Mg alloy powder
Mihir Samantaray1  ; Seshadev Sahoo1  ; Direndranath Thatoi1
1 Department of Mechanical Engineering, Institute of Technical Education and Research, Siksha ‘O’ Anusandhan (Deemed to be University), Odisha, Bhubaneswar-751030, India
Comptes Rendus. Mécanique, Volume 346 (2018) no. 11, pp. 1043-1054.

Direct Metal Laser Sintering (DMLS) is one of the leading additive manufacturing processes, which produces complex metallic parts directly from the powder. One of the major problems of this rapid manufacturing process is an inhomogeneous temperature distribution, which leads to residual stress in the build part. Thus, temperature analyses must be performed, to better understand the temperature distribution and sintering behavior of the powder bed with a different laser recipe. In this study, a comprehensive three-dimensional numerical model was developed to understand the temperature distribution during direct metal laser sintering of AlSi10Mg alloy powder. The computer simulation was carried out in ANSYS 17.0 platform. Further, the effect of process parameters such as laser power and scan speed on the temperature distribution and sintering behavior were studied. From the simulation results, it was found that, when the laser power increased from 70 W to 190 W, the maximum temperature of the molten pool increased from 731 °C to 2672 °C, and the molten pool length changed from 0.286 mm to 2.167 mm. A reverse phenomenon was observed with an increase in scan speed. The sintering depth of the powder layer increases significantly from 0.061 mm to 0.872 mm with increasing the applied laser power, but decreased from 0.973 mm to 0.209 mm as a higher scan speed was applied. The developed model helps to optimize the powder layer thickness and minimize the wastage of excess powders during the sintering process.

Reçu le :
Accepté le :
Publié le :
DOI : 10.1016/j.crme.2018.08.006
Mots clés : Additive manufacturing, Heat transfer, Sintering, Composites
Mihir Samantaray 1 ; Seshadev Sahoo 1 ; Direndranath Thatoi 1

1 Department of Mechanical Engineering, Institute of Technical Education and Research, Siksha ‘O’ Anusandhan (Deemed to be University), Odisha, Bhubaneswar-751030, India 
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Mihir Samantaray; Seshadev Sahoo; Direndranath Thatoi. Computational modeling of heat transfer and sintering behavior during direct metal laser sintering of AlSi10Mg alloy powder. Comptes Rendus. Mécanique, Volume 346 (2018) no. 11, pp. 1043-1054. doi : 10.1016/j.crme.2018.08.006. https://comptes-rendus.academie-sciences.fr/mecanique/articles/10.1016/j.crme.2018.08.006/

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