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CFD Simulation of Fluid Flow During Laser Metal Wire Deposition using OpenFOAM: 3D printing
Luleå University of Technology, Department of Engineering Sciences and Mathematics.
2019 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

The focus of this work was to simulate the fluid flow within a melt pool geometry, during an additive manufacturing process, implementing the CFD software OpenFOAM version 1806. Two separate models were created and run during this work, the first using a temperature mapping from a finite element (FE) model and the second being a free-standing model with Gaussian distributed laser beam striking down on the top surface. Both models were run with the standard solver icoReactingMultiphaseInterFoam, being a multiphase solver, with phase transition possibilities. Addition of gas particles was carried out during post-processing and these were to visualise the imperfections caused by melting metal alloys in a 3D printing case.

During comparison of the movement of the free-standing model, using a moving laser beam, to the mapped temperature FE model, it was revealed that the fluid flow in the molten pool was heavily influenced by the pressure introduced by the laser beam. No streamlines were found that would indicate entrapment of gas particles during solidification.

Abstract [sv]

Fokuset på detta arbete var att simulera vätskeflöde i en smältpool-geometri, under en additiv-tillverkningsprocess. Detta implementerades med hjälp av CFD-mjukvaran OpenFOAM, version 1806. Två separata modeller skapades och simulerades under arbetets gång. Den första modellen kördes med hjälp av en mappning av temperaturfältet från finita-element-modellen (FE-modellen) och den andra modellen var en fristående modell tillsammans med en Gaussisk distribuerad laserstråle riktad ned på översta ytan. Båda simuleringarna använde sig av standardlösaren icoReactingMultiphaseInterFoam, vilket är en multifas-lösare, med möjlighet till fasövergångar. Tillägg av gaspartiklar utfördes under post-processing och dessa var för att visualisera porer som kan uppstå under smältning av metall-legering i en 3D-utskrivningsprocess.

Vid jämförelse av den fristående modellen, som implementerade en rörlig laserstråle, till den mappade FE-modellen, uppdagades det att vätskeflödet i smältpoolen influerades starkt av trycket som orsakades av lasern. Inga strömlinjer tydde på en inkapsling av gaspartiklar under stelning.

Place, publisher, year, edition, pages
2019. , p. 80
National Category
Fluid Mechanics and Acoustics
Identifiers
URN: urn:nbn:se:ltu:diva-74476OAI: oai:DiVA.org:ltu-74476DiVA, id: diva2:1324149
Subject / course
Student thesis, at least 30 credits
Educational program
Engineering Physics and Electrical Engineering, master's level
Supervisors
Examiners
Available from: 2019-06-13 Created: 2019-06-13 Last updated: 2019-06-13Bibliographically approved

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CiteExportLink to record
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