Phase Field Modeling of Coalescence of AlSi10Mg Particles in Direct Metal Laser Sintering

  • Authors

    • Jyotirmoy Nandy
    • Seshadev Sahoo
    • Hrushikesh Sarangi
    • Bibhu Kalyan Panda
    2018-12-13
    https://doi.org/10.14419/ijet.v7i4.39.23956
  • Direct metal laser sintering, coalescence, additive manufacturing, phase field modeling.
  • Direct metal laser sintering (DMLS) is amongst the most proficient technologies in the field of additive manufacturing which produces high quality products. The physical properties of the final products is immensely affected by the process parameters of the process. Being a fast process, the solidification rate is very fast as powdered materials sinter into crystalline structures with the application of laser power. Since the past few decades, computational modeling has helped researchers to predict and optimize the quality of output products. In this study, phase field modeling has been used to study the sintering mechanism and importance of neck growth of AlSi10Mg in DMLS process. Using temperature as an input parameter to study neck growth in equal and  unequal sized particles, it is found that the rise in temperature leads to higher neck growth. It has been found that unequal sized particles experience faster sintering due to high diffusion rate. Also, by increasing the laser power, it has been found that the sintering rate is faster.

     

     

  • References

    1. [1] Gåård, A., Krakhmalev, P. and Bergström, J. (2006) 'Microstructural characterization and wear behavior of (Fe, Ni)–TiC MMC prepared by DMLS', Journal of Alloys and Compounds, Vol. 421, No. 1-2, pp.166-171.

      [2] Calignano, F., Manfredi, D., Ambrosio, E.P., Iuliano, L. and Fino, P. (2013) 'Influence of process parameters on surface roughness of aluminum parts produced by DMLS', The International Journal of Advanced Manufacturing Technology, Vol. 67, No. 9-12, pp.2743-2751.

      [3] Shellabear, M. and Nyrhilä, O. (2004) 'DMLS-Development history and state of the art', Laser Assisted Netshape Engineering 4, Proceedings of the 4th LANE, pp.21-24.

      [4] Nandy, J., Sarangi, H. and Sahoo, S. (2017) 'February. Modeling of microstructure evolution in direct metal laser sintering: A phase field approach', In IOP Conference Series: Materials Science and Engineering, Vol. 178, No. 1, p. 012028.

      [5] Krishnan, M., Atzeni, E., Canali, R., Calignano, F., Manfredi, D., Ambrosio, E. P., & Iuliano, L. (2014) 'On the effect of process parameters on properties of AlSi10Mg parts produced by DMLS', Rapid Prototyping Journal, Vol. 20, No. 6, pp.449-458.

      [6] Fulcher, Benjamin A., David K. Leigh, and Trevor J. Watt (2014) 'Comparison of AlSi10Mg and Al 6061 processed through DMLS', Proceedings of the Solid Freeform Fabrication (SFF) Symposium, Vol. 46.

      [7] Atzeni, E., & Salmi, A. (2015) 'Study on unsupported overhangs of AlSi10Mg parts processed by Direct Metal Laser Sintering (DMLS)', Journal of Manufacturing Processes, Vol. 20, No. 3, pp.500-506.

      [8] Jagota, A., Dawson, P.R. and Jenkins, J.T. (1988), 'An anisotropic continuum model for the sintering and compaction of powder packings', Mechanics of Materials, Vol. 7, No.3, pp.255-269.

      [9] Braginsky, M., Tikare, V. and Olevsky, E. (2005) 'Numerical simulation of solid state sintering', International journal of solids and structures, Vol. 42, No. 2, pp.621-636.

      [10] Thomas, D.A., Lin, Z., Zhigilei, L.V., Gurevich, E.L., Kittel, S. and Hergenröder, R. (2009) 'Atomistic modeling of femtosecond laser-induced melting and atomic mixing in Au film–Cu substrate system', Applied Surface Science, Vol. 255, No. 24, pp.9605-9612.

      [11] Yang, L., Gan, Y., Zhang, Y. and Chen, J.K. (2012) 'Molecular dynamics simulation of neck growth in laser sintering of different-sized gold nanoparticles under different heating rates', Applied Physics A, Vol. 106, No. 3, pp.725-735.

      [12] Jiang, S., Zhang, Y., Gan, Y., Chen, Z. and Peng, H. (2013) 'Molecular dynamics study of neck growth in laser sintering of hollow silver nanoparticles with different heating rates', Journal of Physics D: Applied Physics, Vol. 46, No. 33, p.335302.

      [13] Karma, A. and Rappel, W.J. (1996) 'Phase-field method for computationally efficient modeling of solidification with arbitrary interface kinetics', Physical Review E, Vol. 53, No. 4, p.R3017.

      [14] Mistler, R.E. and Coble, R.L. (1974) 'Grain-boundary diffusion and boundary widths in metals and ceramics', Journal of Applied Physics, Vol. 45, No. 4, pp.1507-1509.

      [15] Johnson, D.L. (1969) 'New Method of Obtaining Volume, Grain-Boundary, and Surface Diffusion Coefficients from Sintering Data', Journal of Applied Physics, Vol. 40, No. 1, pp.192-200.

      [16] Nandy, J., Sarangi, H. and Sahoo, S. (2018) ' Microstructure evolution of Al-Si-10Mg in direct metal laser sintering using phase-field modeling', Advances in Manufacturing, Vol. 6, No. 1, pp.107-117.

      [17] Wang, L.Z., Wang, S. and Wu, J.J. (2017) 'Experimental investigation on densification behavior and surface roughness of AlSi10Mg powders produced by selective laser melting', Optics & Laser Technology, Vol. 96, pp.88-96.

      [18] Biffi, C.A., Fiocchi, J., Bassani, P., Paolino, D.S., Tridello, A., Chiandussi, G., Rossetto, M. and Tuissi, A. (2017) 'Microstructure and preliminary fatigue analysis on AlSi10Mg samples manufactured by SLM', Procedia Structural Integrity, Vol. 7, pp.50-57.

      [19] Takata, N., Kodaira, H., Sekizawa, K., Suzuki, A. and Kobashi, M. (2017) 'Change in microstructure of selectively laser melted AlSi10Mg alloy with heat treatments', Materials Science and Engineering: A, Vol. 704, pp.218-228.

      [20] Bai, Y., Yang, Y., Xiao, Z., Zhang, M. and Wang, D. (2018) 'Process optimization and mechanical property evolution of AlSiMg0. 75 by selective laser melting', Materials & Design, Vol. 140, pp.257-266.

      [21] Steinbach, I., Pezzolla, F., Nestler, B., Seeßelberg, M., Prieler, R., Schmitz, G.J. and Rezende, J.L. (1996) 'A phase field concept for multiphase systems. Physica D: Nonlinear Phenomena', Vol. 94, No. 3, pp.135-147.

      [22] Cahn, J.W., Elliott, C.M. and Novick-Cohen, A. (1996) 'The Cahn–Hilliard equation with a concentration dependent mobility: motion by minus the Laplacian of the mean curvature', European journal of applied mathematics, Vol. 7. No. 3, pp.287-301.

      [23] Zhang, J. and Du, Q. (2009) 'Numerical studies of discrete approximations to the Allen–Cahn equation in the sharp interface limit', SIAM Journal on Scientific Computing, Vol. 31, No. 4, pp.3042-3063.

      [24] Biswas, S., Schwen, D., Singh, J. and Tomar, V. (2016) 'A study of the evolution of microstructure and consolidation kinetics during sintering using a phase field modeling based approach', Extreme Mechanics Letters, Vol. 7, pp.78-89.

      [25] Panda, B.K. and Sahoo, S. (2018) 'Numerical simulation of residual stress in laser based additive manufacturing process', In IOP Conference Series: Materials Science and Engineering, Vol. 338, No. 1, p. 012030.

      [26] Fang, Z.Z.sss ed. (2010) 'Sintering of advanced materials', Elsevier.

  • Downloads

  • How to Cite

    Nandy, J., Sahoo, S., Sarangi, H., & Kalyan Panda, B. (2018). Phase Field Modeling of Coalescence of AlSi10Mg Particles in Direct Metal Laser Sintering. International Journal of Engineering & Technology, 7(4.39), 330-334. https://doi.org/10.14419/ijet.v7i4.39.23956