Numerical simulation and parametric analysis of selective laser melting process of AlSi10Mg powder

A three-dimensional numerical model was developed to investigate effects of laser scanning speed, laser power, and hatch spacing on the thermodynamic behaviors of the molten pool during selective laser melting of AlSi10Mg powder. A randomly distributed packed powder bed was achieved using discrete element method (DEM). The powder bed can be treated as a porous media with interconnected voids in the simulation. A good agreement between numerical results and experimental results establish the validity of adopted method. The numerical results show that the Marangoni flow within the molten pool was significantly affected by the processing parameters. An intense Marangoni flow leads to a perturbation within the molten pool. In addition, a relatively high scanning speed tends to cause melt instability. The perturbation or the instability within the molten pool results in the formation of pores during SLM, which have a direct influence on the densification level.