Numerical Simulations to Predict the Melt Pool Dynamics and Heat Transfer during Single-Track Laser Melting of Ni-Based Superalloy (CMSX-4)

Computational Fluid Dynamics (CFD) simulations are used in this work to study the dynamic behavior of melt pool and heat transfer during single-track laser melting process a nickel-based superalloy (CMSX-4). To include effects powder inhomogeneities obtain realistic distribution layer on bed chamber, CFD model is coupled with Discrete Element Method (DEM) solver. The implemented open-source software package OpenFOAM. In model’s governing equations, some key physical mechanisms, such as Marangoni effect recoil pressure, considered. With help CFD-DEM model, we have investigated parameters, power, scanning speed laser, size, shape, size homogeneity pool. From simulation results, it was discovered that high power slow create deep narrow keyhole leads porosity. contrast, balling defects found be caused by small obtained from fast speeds inadequate power.