Simultaneous modeling of powder rigid motion and molten pool evolution for powder-based additive manufacturing

The rigid motions of powders widely exist in powder-based laser additive manufacturing, like powder deposition, entrainment and spattering. These phenomena simultaneously happen as the laser melts these powders, and can have significant impacts on the quality of the printed products. However, existing models can hardly efficiently reproduce the co-existence of melting and rigid motion which greatly influences the molten pool and molten track evolution. The bottleneck therein lies in the demand that unresolved Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) has on the CFD grid size, that is, larger than 3 times of the particle diameter. However, this large size ratio (CFD grid cell vs particle diameter) handicaps the description of the particle deformation during melting. Hence in this paper, a kernel approximation-based semi-resolved CFD-DEM numerical model that allows the refinement of CFD grid is employed, and then coupled with the Volume of Fluid (VOF) method to reproduce the molten metal-gas interface. On this basis, the rigid motions of the powders, like entrainment and spattering, are finally simultaneously realized as the molten pool evolves at high efficiency. Powders remained in the unclosed molten pool trail defect are well explained with the proposed model as well. This model can also be applied to simulate the particle-fluid interactions in Directed Energy Deposition. It is believed that this semi-resolved VOF-DEM Additive Manufacturing model will serve as a good tool for future investigations into the particle behaviors in powder-based additive manufacturing.