3D Thermal Modelling and Simulation of Ti–6Al–4V alloy Processed by Selective Laser Melting

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Kayacan M. C., Demiray M. A., Baykasoğlu C., Şekerci B.

Additive Manufacturing Conference Turkey, İstanbul, Turkey, 9 - 10 September 2021, vol.1, no.1, pp.1-8

  • Publication Type: Conference Paper / Full Text
  • Volume: 1
  • City: İstanbul
  • Country: Turkey
  • Page Numbers: pp.1-8
  • Süleyman Demirel University Affiliated: Yes


Selective laser melting (SLM) is the most widely used metal additive manufacturing (AM) technique due to its ability to manufacture complex-shaped parts with the desired tolerances. In the present study, a three-dimensional finite element (FE) heat transfer model for the SLM process was developed and multi-track simulations were conducted to predict maximum temperatures and melt pool dimensions depends on the process parameters such as laser power, scanning speed and hatching distance for Ti6Al4V powder. FE simulations for different process parameters were conducted in ABAQUS as it provides a parametric job possibility within its Fortran subroutines. Goldak volumetric laser heat source model was used as the flux source and material properties were revealed as temperature-dependent. During laser scanning, it was observed that powder material is melted by heat source through at least one layer and this leads to interlayer connection as expected. Besides, maximum temperatures were found stable from the beginning to the end of the track until it achieves an equilibrium regime in view of temperature distribution. The fidelty of the simulation was revealed by comparing melt pool dimensions and maximum temperatures with both experimental and simulation studies in the literature. Furthermore, the melt pool depth to width ratios were examined comparing to the literature. Maximum track temperatures rises from 1st track to the last 4th track as in 2550-3250 0C. On the other hand, selected process parameters were pointed out as suitable to fuse laser tracks effectively with its smaller D/W ratio than 0.5 which is possible keyhole limit.