Modelling the influences of powder layer depth and particle morphology on powder bed fusion using a coupled DEM-CFD approach

Optimising the quality of metal parts produced by additive manufacturing requires an understanding of how the powder characteristics impact both layer spreading and the subsequent powder melting. Here we present a simulation study which couples models of powder spreading (by the Discrete Element Method) and powder bed fusion by laser beam (by CFD). Previous simulations of these processes have mostly assumed idealised smooth surfaces, spherical particles and a single laser track. Here we seek a more realistic description by spreading over a previously-melted (rough) surface and by melting a number of tracks laid side-by-side to mimic the crosshatched scans typically used during part production. The effects of powder morphology (via a range of particle shapes including spheres, disks, ellipsoids and cuboids) and layer depth on spreading and subsequent melting have been investigated. We find that the fraction of laser energy transferred to the part and the melt pool volume both increase rapidly with the volume of powder deposited, due to the combined effects of multiple laser reflections and the insulating nature of the powder layer. In contrast, particle shape has very little effect on the overall melting behaviour of the powder, with the volume deposited and uniformity of coverage being the key determining factors. These observations suggest that the use of cheaper non-spherical powders is feasible provided that a sufficiently uniform coverage can be achieved at small layer depths.