金属激光3D打印过程数值模拟应用及研究现状

doi:10.11868/j.issn.1001-4381.2020.000235

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摘要

数值模拟可以高效、有针对性地对金属激光选区熔化成型过程中的温度场、熔池形状、残余应力和变形、凝固过程微观组织演变等过程建立相应的模型并对成形件的相关性能做出准确预测，为工艺优化提供科学的依据，显著降低工艺开发成本和缩短工艺开发周期，有力推动金属增材制造向工业级应用的转变。本文综述了金属激光增材制造过程中温度场、熔池动力学、成形件内部残余应力和变形、显微组织变化4个方面数值模拟的最新研究进展，概述了金属SLM过程数值模拟所取得的最新进展，分析了金属SLM数值模拟领域的研究热点和所存在的计算时间长、成本高等问题，最后提出金属SLM过程数值模拟应将3D打印过程中快速凝固、微熔池等特征与大数据、人工智能、深度学习等技术相结合，进一步提高数值模拟精度，拓宽金属激光增材制造加工窗口，为个性化产品开发提供指导。

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	杨鑫
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关键词 ：金属激光选区熔化, 数值模拟, 温度场, 熔池动力学, 残余应力及变形

Abstract：

Numerical simulation can establish corresponding models for temperature field, molten pool shape, residential stress, microstructure evolution in the metal SLM process effectively. Meanwhile this model can accurately predict the performance of forming parts, and provide scientific basis for process parameters optimization, consequently boost the metal SLM to industry application. In this paper, the latest research progress of numerical simulation in the process of metal laser additive manufacturing was summarized, including temperature field, molten pool dynamics, residual stress and deformation in the forming part, and microstructure change.The latest progress of numerical simulation in metal SLM process was summarized, and the metal SLM process was analyzed. Finally, the future development trend was put forward that metal SLM process numerical simulation should be combined with big data, artificial intelligence, deep learning and other technologies and numerical simulation accuracy will be further improved, the processing window of metal laser additive manufacturing will be broadened, and guidance will be provided for the development of individual products.

Key words： metal selective laser melting numerical simulation temperature fields melting pool dynamics residual stress and deformation

收稿日期: 2020-03-19 出版日期: 2021-04-21

中图分类号:

V261.8

基金资助:国家自然科学基金项目(51671152);国家自然科学基金项目(51874225);国家自然科学基金项目(51504191);国家自然科学基金项目(CXYZKD001);陕西省自然科学基础研究计划项目(2014JM6229);陕西省教育厅产业化项目(18JC091);陕西省教育厅自然科学专项(14JK1512);陕西省自然科学基础研究计划一般青年项目(2020JQ-341)

通讯作者: 杨鑫 E-mail: yangx@xaut.edu.cn

作者简介: 杨鑫(1981-), 男, 副教授, 博士, 主要研究方向为钛合金的3D打印, 联系地址: 陕西省西安市碑林区金花南路5号西安理工大学材料科学与工程学院(710048), E-mail: yangx@xaut.edu.cn

引用本文:

杨鑫, 王犇, 谷文萍, 张兆洋, 刘世锋, 武涛. 金属激光3D打印过程数值模拟应用及研究现状[J]. 材料工程, 2021, 49(4): 52-62.
Xin YANG, Ben WANG, Wen-ping GU, Zhao-yang ZHANG, Shi-feng LIU, Tao WU. Application and research status of numerical simulation of metal laser 3D printing process. Journal of Materials Engineering, 2021, 49(4): 52-62.

链接本文:

http://jme.biam.ac.cn/CN/10.11868/j.issn.1001-4381.2020.000235 或 http://jme.biam.ac.cn/CN/Y2021/V49/I4/52

Fig.1 金属增材制造缺陷类型与形貌^[10]
(a)晶粒内孔缺陷；(b)弧形孔缺陷；(c)熔池夹杂缺陷；(d)层间孔隙缺陷；(e)熔池孔隙缺陷；(f)弧形孔缺陷；(g)不规则孔；(h)孔隙裂纹源缺陷；(i)夹杂裂纹源缺陷

Fig.2 高斯热源模型及实际应用^[9]

Fig.3 粉末随机算法分布模型^[18] (不同颜色表示粉末粒径不同)
(a)粉床分层模型；(b)粉床堆积模型；(c)成型仓粉末填充模型

Fig.4 实验所得熔池温度分布(a)与数值模拟熔池温度场(b)^[22]

Fig.5 激光熔融过程中熔池主要物理过程^[27]

Fig.6 打印参数对熔池大小和形状的影响^[34]

Table 1 成形参数对残余应力的影响^[49-53]

Fig.7 不同能量密度下真实凝固时扫描电镜图像(a), (b)和凝固时相场模拟情况(c), (d)^[58]

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