Cobalt chromium is widely used to make medical implants and wind turbine, engine and aircraft components because of its high wear and corrosion resistance. The ability to process geometrically complex components is an area of intense interest to enable shifting from traditional manufacturing techniques to additive manufacturing (AM). The major reason for using AM is to ease design modification and optimization since AM machines can directly apply the changes from an updated STL file to print a geometrically complex object. Quality assurance for AM fabricated parts is recognized as a critical limitation of AM processes. In selective laser melting (SLM), layer by layer melting and remelting can lead to porosity defects caused by lack of fusion, balling, and keyhole collapse. Machine process parameter optimization becomes a very important task and is usually accomplished by producing a large amount of experimental coupons with different combinations of process parameters such as laser power, speed, hatch spacing, and powder layer thickness. In order to save the cost and time of these experimental trial and error methods, many researchers have attempted to simulate defect formation in SLM. Many physics-based assumptions must be made to model these processes, and thus, all the models are limited in some aspects. In the present work, we investigated single bead melt pool shapes for SLM of CoCr to tune the physics assumptions and then, applied to the model to predict bulk lack of fusion porosity within the finished parts. The simulation results were compared and validated against experimental results and show a high degree of correlation.
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January 2017
Research-Article
Simulating Melt Pool Shape and Lack of Fusion Porosity for Selective Laser Melting of Cobalt Chromium Components
Haijun Gong,
Haijun Gong
Visiting Assistant Professor,
Georgia Southern University,
Statesboro, GA 30460
Georgia Southern University,
Statesboro, GA 30460
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Attila Szabo,
Attila Szabo
GE Power & Water,
Greenville, SC 29615
Greenville, SC 29615
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J. J. S. Dilip,
J. J. S. Dilip
University of Louisville,
Louisville, KY 40292
Louisville, KY 40292
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Shanshan Zhang,
Shanshan Zhang
University of Louisville,
Louisville, KY 40292
Louisville, KY 40292
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Nachiket Patil,
Nachiket Patil
3DSIM,
LLC,
Park City, UT 84098,
LLC,
Park City, UT 84098,
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Deepankar Pal,
Deepankar Pal
3DSIM,
LLC,
Park City, UT 84098;
LLC,
Park City, UT 84098;
University of Louisville,
Louisville, KY 40292,
Louisville, KY 40292,
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Brent Stucker
Brent Stucker
3DSIM,
LLC,
Park City, UT 84098
LLC,
Park City, UT 84098
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Chong Teng
Haijun Gong
Visiting Assistant Professor,
Georgia Southern University,
Statesboro, GA 30460
Georgia Southern University,
Statesboro, GA 30460
Attila Szabo
GE Power & Water,
Greenville, SC 29615
Greenville, SC 29615
J. J. S. Dilip
University of Louisville,
Louisville, KY 40292
Louisville, KY 40292
Katy Ashby
3DSIM,
LLC,
Park City, UT 84098
LLC,
Park City, UT 84098
Shanshan Zhang
University of Louisville,
Louisville, KY 40292
Louisville, KY 40292
Nachiket Patil
3DSIM,
LLC,
Park City, UT 84098,
LLC,
Park City, UT 84098,
Deepankar Pal
3DSIM,
LLC,
Park City, UT 84098;
LLC,
Park City, UT 84098;
University of Louisville,
Louisville, KY 40292,
Louisville, KY 40292,
Brent Stucker
3DSIM,
LLC,
Park City, UT 84098
LLC,
Park City, UT 84098
Manuscript received January 6, 2016; final manuscript received June 14, 2016; published online August 10, 2016. Assoc. Editor: Y. B. Guo.
J. Manuf. Sci. Eng. Jan 2017, 139(1): 011009 (11 pages)
Published Online: August 10, 2016
Article history
Received:
January 6, 2016
Revised:
June 14, 2016
Citation
Teng, C., Gong, H., Szabo, A., Dilip, J. J. S., Ashby, K., Zhang, S., Patil, N., Pal, D., and Stucker, B. (August 10, 2016). "Simulating Melt Pool Shape and Lack of Fusion Porosity for Selective Laser Melting of Cobalt Chromium Components." ASME. J. Manuf. Sci. Eng. January 2017; 139(1): 011009. https://doi.org/10.1115/1.4034137
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