Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep Optimization
ABSTRACT Selective laser melting (SLM) process offers a versatile additive manufacturing technology. However, the wide range of process parameters and complex thermophysical phenomenon necessitate optimization of process parameters for obtaining a high‐quality finished product. The optimization of p...
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2025-01-01
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| Online Access: | https://doi.org/10.1002/eng2.13040 |
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| author | Kidu Gebrecherkos Weldeanenia Samuel Kinde Kassegne Perumalla Janaki Ramulu |
| author_facet | Kidu Gebrecherkos Weldeanenia Samuel Kinde Kassegne Perumalla Janaki Ramulu |
| author_sort | Kidu Gebrecherkos Weldeanenia |
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| description | ABSTRACT Selective laser melting (SLM) process offers a versatile additive manufacturing technology. However, the wide range of process parameters and complex thermophysical phenomenon necessitate optimization of process parameters for obtaining a high‐quality finished product. The optimization of process parameters through experiment is expensive and time‐consuming. On the other hand, computational approaches offer a fast and economical way to predict the contributions of process parameters. In this article, therefore, a multiphysics finite‐element model and phase‐filed model of solidification process were used to investigate the effects of process parameters on the melt pool solidification parameters and microstructure evolution of SLM‐Ti6Al4V process. Simulations were performed using the single‐level setup method followed by a parametric sweep optimization (PSO) approach that helped identify the best‐suited process parameters. Through the PSO, reductions in temperature gradient by 9.7% and 13.7%, and cooling rate by 23.6% and 14.3% were found at a fixed laser scan speed and laser power, respectively. The associated solidification morphology factor was found to be 5.8 × 105 Ks/m2. In addition, the primary dendrite arm spacing (PDAS) was found to be at 3.6% and 6.8% increments at a fixed laser speed and laser power, respectively. Finally, optimal results of the solidification parameters were compared with the existing data to validate the approach. The simulation results have been shown that reduction in the temperature gradient by 28.5%, cooling rate by 48.6%, and solidification morphology factor by 3.3% tend to minimize fluctuation of melt pool. The comparisons have also shown that the PSO approach is effective and accurate for predicting the solidification behaviors of SLM‐Ti6Al4V process. |
| format | Article |
| id | doaj-art-ec9b853a1c074895a69aa409ba8a024e |
| institution | Kabale University |
| issn | 2577-8196 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Wiley |
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| series | Engineering Reports |
| spelling | doaj-art-ec9b853a1c074895a69aa409ba8a024e2025-01-31T00:22:48ZengWileyEngineering Reports2577-81962025-01-0171n/an/a10.1002/eng2.13040Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep OptimizationKidu Gebrecherkos Weldeanenia0Samuel Kinde Kassegne1Perumalla Janaki Ramulu2Department of Mechanical Engineering, School of Mechanical, Chemical and Materials Engineering Adama EthiopiaDepartment of Mechanical Engineering San Diego State University San Diego California USADepartment of Mechanical Engineering, School of Mechanical, Chemical and Materials Engineering Adama EthiopiaABSTRACT Selective laser melting (SLM) process offers a versatile additive manufacturing technology. However, the wide range of process parameters and complex thermophysical phenomenon necessitate optimization of process parameters for obtaining a high‐quality finished product. The optimization of process parameters through experiment is expensive and time‐consuming. On the other hand, computational approaches offer a fast and economical way to predict the contributions of process parameters. In this article, therefore, a multiphysics finite‐element model and phase‐filed model of solidification process were used to investigate the effects of process parameters on the melt pool solidification parameters and microstructure evolution of SLM‐Ti6Al4V process. Simulations were performed using the single‐level setup method followed by a parametric sweep optimization (PSO) approach that helped identify the best‐suited process parameters. Through the PSO, reductions in temperature gradient by 9.7% and 13.7%, and cooling rate by 23.6% and 14.3% were found at a fixed laser scan speed and laser power, respectively. The associated solidification morphology factor was found to be 5.8 × 105 Ks/m2. In addition, the primary dendrite arm spacing (PDAS) was found to be at 3.6% and 6.8% increments at a fixed laser speed and laser power, respectively. Finally, optimal results of the solidification parameters were compared with the existing data to validate the approach. The simulation results have been shown that reduction in the temperature gradient by 28.5%, cooling rate by 48.6%, and solidification morphology factor by 3.3% tend to minimize fluctuation of melt pool. The comparisons have also shown that the PSO approach is effective and accurate for predicting the solidification behaviors of SLM‐Ti6Al4V process.https://doi.org/10.1002/eng2.13040fluctuation reductionmicrostructure evolution indicatoroptimum process parametersparametric sweep optimizationSLM‐Ti6Al4V alloy simulationsolidification parameters |
| spellingShingle | Kidu Gebrecherkos Weldeanenia Samuel Kinde Kassegne Perumalla Janaki Ramulu Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep Optimization Engineering Reports fluctuation reduction microstructure evolution indicator optimum process parameters parametric sweep optimization SLM‐Ti6Al4V alloy simulation solidification parameters |
| title | Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep Optimization |
| title_full | Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep Optimization |
| title_fullStr | Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep Optimization |
| title_full_unstemmed | Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep Optimization |
| title_short | Governing of Melt Pool Solidification Parameters and Microstructure Evolution Indicator During SLM‐Ti6Al4V Alloy Through Parametric Sweep Optimization |
| title_sort | governing of melt pool solidification parameters and microstructure evolution indicator during slm ti6al4v alloy through parametric sweep optimization |
| topic | fluctuation reduction microstructure evolution indicator optimum process parameters parametric sweep optimization SLM‐Ti6Al4V alloy simulation solidification parameters |
| url | https://doi.org/10.1002/eng2.13040 |
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