Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing

Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing

2024 | ROBERT MOORE,1 GIOVANNI ORLANDI,2 THERON RODGERS,3 DANIEL MOSER,3 HEATHER MURDOCH,4 and FADI ABDELJAWAD 5
The article "Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing" by Robert Moore, Giovanni Orlandi, Theron Rodgers, Daniel Moser, Heather Murdoch, and Fadi Abdeljawad explores the impact of different laser beam profiles on the microstructure development during laser powder bed fusion (LPBF) additive manufacturing. The authors use a coupled thermal transport-Monte Carlo model to predict the evolution of temperature fields and grain microstructures using Gaussian, ring, and Bessel beam profiles. Key findings include: 1. **Temperature Fields**: The ring-shaped beam results in lower temperatures compared to the Gaussian beam. 2. **Grain Microstructures**: The Bessel beam, due to its small melt pool size, produces smaller and more equiaxed grains compared to the Gaussian and ring beams. 3. **Process-Structure Linkages**: The study provides insights into how laser beam shaping influences microstructure development, offering future avenues for predicting the impact of different beam profiles on LPBF. The introduction highlights the importance of additive manufacturing (AM) in various applications and the role of LPBF in fabricating metallic systems. It discusses the challenges in controlling microstructure formation through process parameters and the potential of using spatially extended laser beam profiles to manipulate temperature fields and microstructures. The methods section outlines the mesoscale modeling framework used, including the heat transfer model and the intensity profiles of the different laser beams.The article "Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing" by Robert Moore, Giovanni Orlandi, Theron Rodgers, Daniel Moser, Heather Murdoch, and Fadi Abdeljawad explores the impact of different laser beam profiles on the microstructure development during laser powder bed fusion (LPBF) additive manufacturing. The authors use a coupled thermal transport-Monte Carlo model to predict the evolution of temperature fields and grain microstructures using Gaussian, ring, and Bessel beam profiles. Key findings include: 1. **Temperature Fields**: The ring-shaped beam results in lower temperatures compared to the Gaussian beam. 2. **Grain Microstructures**: The Bessel beam, due to its small melt pool size, produces smaller and more equiaxed grains compared to the Gaussian and ring beams. 3. **Process-Structure Linkages**: The study provides insights into how laser beam shaping influences microstructure development, offering future avenues for predicting the impact of different beam profiles on LPBF. The introduction highlights the importance of additive manufacturing (AM) in various applications and the role of LPBF in fabricating metallic systems. It discusses the challenges in controlling microstructure formation through process parameters and the potential of using spatially extended laser beam profiles to manipulate temperature fields and microstructures. The methods section outlines the mesoscale modeling framework used, including the heat transfer model and the intensity profiles of the different laser beams.
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[slides and audio] Microstructure-Based Modeling of Laser Beam Shaping During Additive Manufacturing