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Thermo-Fluid Characterizations of Ti-6Al-4V Melt Pool in Powder-Bed Electron Beam Additive Manufacturing

[+] Author Affiliations
M. Shafiqur Rahman, Paul J. Schilling, Paul D. Herrington, Uttam K. Chakravarty

University of New Orleans, New Orleans, LA

Paper No. IMECE2016-65854, pp. V001T03A016; 9 pages
  • ASME 2016 International Mechanical Engineering Congress and Exposition
  • Volume 1: Advances in Aerospace Technology
  • Phoenix, Arizona, USA, November 11–17, 2016
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-5051-0
  • Copyright © 2016 by ASME


The powder-bed electron beam additive manufacturing (EBAM) process is one of the relatively new additive manufacturing (AM) technologies in which the metal powder is melted in a vacuum environment utilizing a high-energy heat source to fabricate metallic parts in a layer by layer manner. Different metallic alloys (especially, high entropy alloys such as Ti-6Al-4V) have been widely studied as a powder-bed material for the EBAM. Despite the unique advantages of designing complex geometry and tooling-free manufacturing, there are still considerable challenges in the EBAM, e.g., obtaining desired metallurgical behavior, part accuracy, reliability, and quality consistency. Therefore, a better understanding of the thermo-fluid and mechanical properties of the EBAM process is indispensable to meet the challenges. In this study, transient computational fluid dynamics (CFD) modeling of Ti-6Al-4V melt pool has been done using ANSYS Fluent 15.0 to characterize the process parameters associated with the EBAM process including the melt pool geometry, beam power, beam speed, beam diameter, and temperature profile along the melt scan. In fact, the dynamics and the solidification of the melt pool have been investigated numerically and results for cooling rate, variation in density, pressure, velocities, and liquid fraction have been obtained to illustrate the versatility of the analysis.

Copyright © 2016 by ASME



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