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Engineering    2017, Vol. 3 Issue (5) : 701 -707
Research |
Modeling and Experimental Validation of the Electron Beam Selective Melting Process
Wentao Yan1,2,Ya Qian1,Weixin Ma3,Bin Zhou1,Yongxing Shen3,Feng Lin1()
1. Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
2. Department of Mechanical Engineering, Northwestern University, Evanston, IL 60201, USA
3. State Key Lab of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai 200240, China

Electron beam selective melting (EBSM) is a promising additive manufacturing (AM) technology. The EBSM process consists of three major procedures: ① spreading a powder layer, ② preheating to slightly sinter the powder, and ③ selectively melting the powder bed. The highly transient multi-physics phenomena involved in these procedures pose a significant challenge for in situ experimental observation and measurement. To advance the understanding of the physical mechanisms in each procedure, we leverage high-fidelity modeling and post-process experiments. The models resemble the actual fabrication procedures, including ① a powder-spreading model using the discrete element method (DEM), ② a phase field (PF) model of powder sintering (solid-state sintering), and ③ a powder-melting (liquid-state sintering) model using the finite volume method (FVM). Comprehensive insights into all the major procedures are provided, which have rarely been reported. Preliminary simulation results (including powder particle packing within the powder bed, sintering neck formation between particles, and single-track defects) agree qualitatively with experiments, demonstrating the ability to understand the mechanisms and to guide the design and optimization of the experimental setup and manufacturing process.

Keywords Modeling      Electron beam      Additive manufacturing      Powder scale     
Corresponding Authors: Feng Lin   
Online First Date: 06 November 2017    Issue Date: 08 November 2017
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Wentao Yan
Ya Qian
Weixin Ma
Bin Zhou
Yongxing Shen
Feng Lin
Cite this article:   
Wentao Yan,Ya Qian,Weixin Ma, et al. Modeling and Experimental Validation of the Electron Beam Selective Melting Process[J]. Engineering, 2017, 3(5): 701 -707 .
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