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金属学报    DOI: 10.11900/0412.1961.2025.00343
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基于计算流体力学-离散单元法的激光粉末床熔融过程中熔池-飞溅耦合动力学行为
曹流, 姚权鸿
广州大学 机械与电气工程学院  广州 510006
Coupled Dynamic Behavior of Molten Pool-Spatter During Laser Powder Bed Fusion Based on Computational Fluid Dynamics-Discrete Element Method
CAO Liu, YAO Quanhong
School of Mechanical and Electrical Engineering, Guangzhou University, Guangzhou 510006, China
引用本文:

曹流, 姚权鸿. 基于计算流体力学-离散单元法的激光粉末床熔融过程中熔池-飞溅耦合动力学行为[J]. 金属学报, DOI: 10.11900/0412.1961.2025.00343.

全文: PDF(2421 KB)  
摘要: 
激光粉末床熔融(LPBF)通过逐层加工为精密金属零件创新设计提供了制造自由度,但所伴随的飞溅会污染粉末床、引入冶金缺陷,并影响工艺稳定性。本工作采用基于计算流体力学-离散单元法(CFD-DEM)的开源平台CFDEM开展了LPBF熔池-飞溅耦合动力学行为数值模拟研究。再现了金属颗粒的三种典型行为(热飞溅、受激光加热作用熔入熔池以及未受激光加热作用掉入熔池),预测了不同工艺参数下的飞溅喷射方向,并与实验结果进行了对比验证。研究了工艺参数对熔池-飞溅耦合动力学行为的影响,结果表明,各工艺参数对热飞溅数目影响的重要性顺序为:粉床厚度>扫描速率>激光功率。本工作的开源代码网址为https://github.com/caoliu0706/7-CFD-DEM-LPBF-Molten-Pool-Splatter
关键词 激光粉末床熔融飞溅熔池CFD-DEMEuler-Lagrange方法数值模拟    
Abstract

Laser powder bed fusion (LPBF) offers manufacturing freedom for innovative designs of precision metal parts via layer-by-layer processing. However, the accompanying spatter during manufacturing contaminates the powder bed, introduces metallurgical defects, and compromises overall stability. To address these issues, this study numerically simulates the coupled dynamic behavior of LPBF molten-pool spatter based on the computational fluid dynamics-discrete element method (CFD-DEM) framework implemented the CFDEM open-source platform. The CFD calculation distinguishes between the liquid–metal, solid–metal, and gas phases using the volume of fluid and multiphase models, while the DEM calculation addresses metal particles, accounting for the influence of metal-vapor recoil force on particle motion. Employing a semianalytical CFD-DEM approach, this coupling framework circumvents the limitation imposed by the CFD mesh size. The simulation reproduced three typical behaviors of metal particles (thermal spatter, melting into the molten pool under laser heating, and falling into the molten pool without laser heating) and predicted the spatter-ejection directions under different process parameters. The numerical results were verified through comparisons with the experimental results. Finally, the influence of process parameters on the coupled dynamic behavior of molten-pool spatter was investigated, revealing that powder bed thickness dominantly affects the number of hot spatters, followed by scanning speed and laser power. The open-source code of this paper is available at https://github.com/caoliu0706/7-CFD-DEM-LPBF-Molten-Pool-Splatter.

Key wordsLaser Powder Bed Fusion    spatter    molten pool    CFD-DEM    Euler-Lagrange method    numerical simulation
收稿日期: 2025-10-27     
基金资助:国家自然科学基金(52405348); 广东省自然科学基金项目(2025A1515010876)
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