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研究生：	黎仲仁 Le, Trong-Nhan
論文名稱：	金屬積層製造領域多尺度和多物理狀態之數值模擬 Multi-scale and multi-physics numerical simulation in Powder-based Metallic Additive Manufacturing
指導教授：	羅裕龍 Lo, Yu-Lung
學位類別：	博士 Doctor
系所名稱：	工學院 - 機械工程學系 Department of Mechanical Engineering
論文出版年：	2021
畢業學年度：	109
語文別：	英文
論文頁數：	188
中文關鍵詞：	雷射粉床熔融、電子束熔化、凝固和熔化、流體粒子交互作用、電子束吸收率
外文關鍵詞：	Laser Powder Bed Fusion, Electron Beam Melting, solidification and melting, fluid-particle interaction, electron beam absorption
相關次數：	點閱：160 下載：0
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基於粉床的積層製造技術，如雷射粉床熔融或電子束熔化，在過去十年中已經徹底改變了製造業，因為此技術能夠在不需要額外工具下生產具有高度複雜幾何形狀的金屬零件。此外，由於這些製程固有的定向快速熔化以及凝固的現象，與傳統的製造技術如鑄造以及鍛造相比，列印的零件具有獨特的機械與微觀結構特性。因此，列印參數可用來定制同一構件內的機械和微觀結構變化，為4D打印技術鋪路。儘管為各個工業領域帶來了眾多優勢，此技術仍然面臨著許多跳戰，從構件的品質、製程的穩定性和一致性，到輕質材料或易裂材料的可印製性，造成這些障礙的主要原因是在列印過程中發生了無數物理現象的複雜相互作用，熱源-物質相互作用、快速融化和凝固、熔池以及腔體的流體力學、刮刀和流場引起的粒子動力學、材料的蒸發冷凝、微觀結構演變和殘餘應力累積是造成列印過程複雜性的主要物理現象，僅舉幾例。全面了解這些物理原理、交互作用以及對於列印零件的影響，不僅是控制製程品質和穩定性的關鍵，而且是開啟製造具有獨特微觀結構和機械性能的能力，這對於傳統製造技術是難以達到的。隨著電腦硬體設備的進步，電腦計算方法已成為研究人員揭示這些物理現象潛在機制的首選方法，而最終目標為製成優化以及客製化。本論文致力於使用廣泛的數值模擬來揭示該製程中一些最重要的物理現象，如材料的快速熔化凝固、熔池和腔體內部的流體力學、由於金屬蒸氣動力學以及材料對於電子束的吸收率所帶來的粉末夾帶、噴濺、剝蝕等。本論文有助於理解過程以及製程的優化及客製化。此外，研究結果可以為3D列印輕質材料鋪路，例如鎂，其可印製性仍然是最大的挑戰。

Powder bed based additive manufacturing technologies such as Laser Powder Bed Fusion (L-PBF) or Selective Electron Beam Melting (SEBM) have been revolutionizing the manufacturing industry for the past decade with their ability to produce functional metallic components with highly complex geometry without the need for additional tooling. In addition, due to the intrinsic directional rapid melting and solidification phenomenon of those processes, the printed parts possess unique sets of mechanical and microstructural properties compared to conventional manufacturing techniques such as casting or wrought. Hence, the printing parameters can be used to tailor the mechanical and microstructural variation within the same built part, paving the way to 4-D printing. Despite a multitude of advantages brought to various industrial fields, the technology still has a wide range of challenges from the quality of the built part, the stability and consistency of the process, to the printability of light-weight materials or crack-prone materials. The primary cause for those obstacles is the complex interplay of a myriad of physics occurring during the printing process. Heat source-matter interactions, rapid melting and solidification, fluid dynamics in both melt-pool and in the chamber, particle dynamics induced by the spreader and the flow field, evaporation and condensation of materials, microstructure evolution, and residual stress accumulation are some primary physics contributing to the complex of the printing process, just to name a few. Acquiring a full understanding of those physics, their interplays, and their effects on the printed parts is the key to not only control the quality and stability of the process but also unlock the ability to manufacture components with unique microstructural and mechanical properties that is impossible for conventional manufacturing techniques to deliver. With the advances of computer hardware, computational methods have been the weapon of choice for researchers to reveal the underlying mechanism of those physical phenomena with the final goal is process optimization and customization. This thesis is dedicated to use a wide range of numerical simulations to unveil some of the most important physics in the process such as the rapid melting and solidification of materials, the fluid dynamics inside the melt-pool and inside the chamber, the complex physics of powder entrainment, spatter and denudation formation due to the dynamics of metal vapor, and the absorption to electron beam of materials. The outputs of this thesis assist significantly to the understanding of the process, hence, contributing to the optimization and customization of the process as well. In addition, obtained results in this work may pave a way to 3-D print light-weight materials such as magnesium whose printability remains the biggest challenge.

ACKOWLEDGEMENT	I
ABSTRACT	II
中文摘要	IV
LIST OF FIGURE	XI
LIST OF TABLE	XIX
CHAPTER 1  INTRODUCTION	1
1		Research background	1
2		Literature review of the simulation of melting and solidification of the L-PBF process	4
3		Literature review of the particle-fluid interactions inside the L-PBF chamber					7
4		Literature review of the monitoring system development for the L-PBF process				10
5		Literature review of the heat source modelling for the SEBM process	13
6		Motivation and structure of this study	15
CHAPTER 2  EFFECTS OF SULFUR CONCENTRATION AND MARANGONI CONVECTION ON MELT-POOL FORMATION IN TRANSITION MODE OF L-PBF PROCESS	18
1.	Marangoni effect	18
1.1.	Effect of sulfur content on surface tension gradient (dγ/dT)	18
1.2.	Estimation of surface tension gradient (dγ/dT)	21
2.	Three-dimensional thermal-fluid model	21
3.	Verification of simulation model with experimental data in [92]	30
4.	Experimental procedure and results	40
5.	Conclusions	48
CHAPTER 3  NUMERICAL SIMULATION AND EXPERIMENTAL VALIDATION OF MELTING AND SOLIDIFICATION PROCESS IN LASER POWDER BED FUSION OF IN718 ALLOY	51
1.	Three-dimensional heat-and-mass transfer simulation model	51
1.1.	Basic assumptions	51
1.2.	Governing equations	53
1.3.	Volumetric heat source	55
1.4.	Modeling of melting and solidification processes in L-PBF treatment of IN718		57
1.5.	Initial conditions and boundary conditions	60
1.6.	Numerical solution procedure	62
2.	In-situ monitoring system for measuring melt-pool length and above-substrate width		64
3.	Results and discussions	67
3.1.	Melt-pool depth and below-substrate width	67
3.2.	Melt-pool length and above-substrate width	72
4.	Conclusions	77
CHAPTER 4  NUMERICAL INVESTIGATION ON THE POWDER ENTRAINMENT, DENUDATION, AND SPATTERING IN LASER POWDER BED FUSION PROCESS	80
1.	CFD-DEM coupled simulation	81
1.1.	Important assumptions	81
1.2.	Computational fluid dynamics (CFD)	81
1.3.	Discrete element method (DEM)	82
1.4.	CFD-DEM two-way coupling of momentum and energy	84
1.5.	Domain description	85
2.	Results and discussions	88
2.1.	Typical simulations	88
2.2.	Effects of spouting angle, chamber pressure, and gravitational force on the denudation and spatter suppression	99
3.	Conclusions	108
CHAPTER 5  VISION-BASED IN-SITU MONITORING SYSTEM FOR MELT-POOL DETECTION IN LASER POWDER BED FUSION PROCESS	110
1.	Proposed Melt-Pool Boundary Detection Method	110
1.1.	Perspective transformation and spatial resolution calibration	110
1.2.	Dilation process for spatter removal	112
1.3.	Melt-pool boundary detection using intensity gradient approach	114
2.	Experimental Setup	118
3.	Experimental results	120
3.1.	Experimental results for IN718	120
3.2.	Experimental results for SS316L	125
4.	Conclusions and future work	127
CHAPTER 6  MULTI-SCALE MODELING OF SELECTIVE ELECTRON BEAM MELTING OF TI6AL4V TITANIUM ALLOY	129
1.	The volumetric heat source for powder-bed SEBM process	129
1.1.	The effective interaction modeling of electron-atom interactions via Monte Carlo simulation at the microscale	131
1.2.	Mesoscale simulation with powder bed model implementation	136
1.3.	Volumetric heat source	141
2.	Material properties	142
3.	Macroscale heat transfer simulations	144
3.1.	Mathematical model	144
3.2.	Finite element method	145
4.	Results and Discussions	147
4.1.	Typical simulation results	147
4.2.	Model validation	148
5.	Conclusions	159
CHAPTER 7  CONCLUSIONS AND FUTURE WORKS	161
1.	Conclusions	161
2.	Future works	162
LIST OF JOURNAL PAPER	163
LIST OF CONFERENCE PAPER	164
LIST OF AWARDS	165
REFERENCES	166
                                    

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