Finite element analysis of thermal behavior and experimental investigation of Ti6Al4V in selective laser melting

Abstract The selective laser melting (SLM) has always been a challenge due to the characteristics of extremely rapid melting and solidification in the micro melt pool. Therefore, a three-dimensional finite element model was developed to investigate the thermal history and solidification parameters in the SLM process. The model presents the temperature distribution, molten region dimensions under different process parameters. The width, depth and length of molten region are inversely proportional to the laser power and scan speed. And then, the variations of solidification parameters with different laser power and scan speeds was discussed. The temperature gradient is mainly affected by laser power and decreases with the increase of laser power; the solidification rate is proportional to the scan speed. The cooling rate decreases progressively with the increase of the linear energy density while solidification morphology parameter is inversely proportional to laser power and scan speed, but fluctuates with the change of linear energy density. Single-track experiments demonstrate the accuracy and effectiveness of the model. Besides, surface quality can be improved with the increase of linear energy input in a certain range.