Gradient models of moving heat sources for powder bed fusion applications

TL;DR

This paper develops gradient heat transfer models with closed-form solutions for moving heat sources, enabling refined analysis of melt pool shapes in laser powder bed fusion, accounting for powder particle size effects.

Contribution

It introduces a generalized gradient heat transfer model with singularity-free solutions for moving heat sources, linking the model's length scale to powder particle size.

Findings

Model describes decrease in melt pool depth with larger powder particles

Provides dimensionless relations for experimental parameter identification

Semi-analytical solutions for Gaussian laser beams are derived

Abstract

In this paper, we derive closed form solutions for the quasi-stationary problems of moving heat sources within the gradient theory of heat transfer. This theory can be formally deduced from the two-temperature model and it can be treated as a generalized variant of the Guyer-Krumhansl model with the fourth order governing equation. We show that considered variant of the gradient theory allows to obtain a useful singularity-free solutions for the moving point and line heat sources that can be used for the refined analysis of the melt pool shape in the laser powder bed fusion processes. Derived solutions contain single additional length scale parameter that can be related to the mean particles size of the powder bed. Namely, we show that developed gradient models allow to describe the decrease of the melt pool depth with the increase of the powder's particles size that was observed previously in the experiments. We also derive the dimensionless relations that can be used for the experimental identification of the model's length scale parameter for different materials. Semi-analytical solution for the Gaussian laser beam is also derived and studied based on the Green function method within the considered theory.