Dimensionless numbers in additive manufacturing

T. Mukherjee, V. Manvatkar, A. De, Tarasankar Debroy

Research output: Contribution to journalArticle

23 Citations (Scopus)

Abstract

The effects of many process variables and alloy properties on the structure and properties of additively manufactured parts are examined using four dimensionless numbers. The structure and properties of components made from 316 Stainless steel, Ti-6Al-4V, and Inconel 718 powders for various dimensionless heat inputs, Peclet numbers, Marangoni numbers, and Fourier numbers are studied. Temperature fields, cooling rates, solidification parameters, lack of fusion defects, and thermal strains are examined using a well-tested three-dimensional transient heat transfer and fluid flow model. The results show that lack of fusion defects in the fabricated parts can be minimized by strengthening interlayer bonding using high values of dimensionless heat input. The formation of harmful intermetallics such as laves phases in Inconel 718 can be suppressed using low heat input that results in a small molten pool, a steep temperature gradient, and a fast cooling rate. Improved interlayer bonding can be achieved at high Marangoni numbers, which results in vigorous circulation of liquid metal, larger pool dimensions, and greater depth of penetration. A high Fourier number ensures rapid cooling, low thermal distortion, and a high ratio of temperature gradient to the solidification growth rate with a greater tendency of plane front solidification.

Original languageEnglish (US)
Article number064904
JournalJournal of Applied Physics
Volume121
Issue number6
DOIs
StatePublished - Feb 14 2017

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dimensionless numbers
solidification
Inconel (trademark)
manufacturing
cooling
heat
interlayers
temperature gradients
fusion
Laves phases
Peclet number
defects
liquid metals
fluid flow
intermetallics
stainless steels
tendencies
temperature distribution
penetration
heat transfer

All Science Journal Classification (ASJC) codes

  • Physics and Astronomy(all)

Cite this

Mukherjee, T. ; Manvatkar, V. ; De, A. ; Debroy, Tarasankar. / Dimensionless numbers in additive manufacturing. In: Journal of Applied Physics. 2017 ; Vol. 121, No. 6.
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Dimensionless numbers in additive manufacturing. / Mukherjee, T.; Manvatkar, V.; De, A.; Debroy, Tarasankar.

In: Journal of Applied Physics, Vol. 121, No. 6, 064904, 14.02.2017.

Research output: Contribution to journalArticle

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