Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing

Moore, Robert; Orlandi, Giovanni; Rodgers, Theron; Moser, Daniel Robert; Murdoch, Heather; Abdeljawad, Fadi

doi:10.1007/s11837-023-06363-8

Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing

Journal Article · Sun Jan 21 23:00:00 EST 2024 · JOM. Journal of the Minerals, Metals & Materials Society

DOI:https://doi.org/10.1007/s11837-023-06363-8· OSTI ID:2329574

Moore, Robert ^[1]; Orlandi, Giovanni ^[2]; ^[3]; Moser, Daniel Robert ^[3]; Murdoch, Heather ^[4]; ^[5]

Lehigh Univ., Bethlehem, PA (United States)
Clemson Univ., SC (United States)
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
DEVCOM Army Research Laboratory, MD (United States)
Lehigh Univ., Bethlehem, PA (United States); Clemson Univ., SC (United States)

Recent experimental studies suggest the use of spatially extended laser beam profiles as a strategy to control the melt pool during laser powder bed fusion (LPBF) additive manufacturing. However, linkages connecting laser beam profiles to thermal fields and resultant microstructures have not been established. Herein, we employ a coupled thermal transport-Monte Carlo model to predict the evolution of temperature fields and grain microstructures during LPBF using Gaussian, ring, and Bessel beam profiles. In addition, simulation results reveal that the ring-shaped beam yields lower temperatures compared with the Gaussian beam. Owing to the small melt pool size when using the Bessel beam, the grains are smaller in size and more equiaxed compared to those using the Gaussian and ring beams. Our approach provides future avenues to predict the impact of laser beam shaping on microstructure development during LPBF.

View Accepted Manuscript (DOE)

Research Organization:: Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE Laboratory Directed Research and Development (LDRD) Program; National Science Foundation (NSF); US Army Research Laboratory (USARL); USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: NA0003525

OSTI ID:: 2329574

Report Number(s):: SAND--2024-03768J

Journal Information:: JOM. Journal of the Minerals, Metals & Materials Society, Journal Name: JOM. Journal of the Minerals, Metals & Materials Society Journal Issue: 3 Vol. 76; ISSN 1047-4838

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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