Defects including the pores and cracks significantly degrade the properties of as-built parts. The molten pool flow, particularly the keyhole effect, plays a key role in the defects that are difficult to observe through experiments in the selective laser melting process. In this study, we derived a new formulation of evaporation for metal alloys from thermodynamics considering the chemical compositions, and the formation of the keyhole was simulated using the Finite Volume Method (FVM) with the Volume of Fraction method to track the gas-liquid interface, where the multi-reflection of the laser within the keyhole and powder bed was incorporated using a ray-tracing algorithm. The geometry features of the simulated keyhole and melting pool showed a good agreement with the experimental observation by ultrahigh-speed X-ray imaging in Argonne National Lab. To understand the physical mechanisms of the keyhole, the laser energy distribution on the keyhole surface, and the driving forces (e.g. Marangoni force, recoil pressure) on the keyhole surface were further analyzed. The laser scanning simulations on a bare plate under external magnetic fields indicate that the Lorentz force can smooth the fluid flow field in the molten pool and increase the ratio of equiaxed grains in the solidication front.

Evaporation Model for Keyhole Dynamics During Additive Manufacturing of Metal

**Session Chair: **Hortense Le Ferrand

SYM O - Materials for Additive Manufacturing

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Evaporation Model for Keyhole Dynamics During Additive Manufacturing of Metal

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