Numerical analysis of heat transfer during multi-layer selective laser melting of AlSi10Mg

A three-dimensional finite element model is developed to simulate multi-layer deposition of AlSi10Mg in selective laser melting (SLM) by using commercial ANSYS software. The temperature distribution, thermal history, molten pool depth, remelting depth, cooling rate and solidification morphology parameter in multi-layer buildup process are investigated. Furthermore, the effect of laser energy input on the melting and solidification process is evaluated. The results show that the temperature and molten pool depth gradually increases with new layers and energy input. The cooling rate increases progressively while the solidification morphology parameter decreases with the increase of energy input. It leads to obtain fine grains with low energy input. To verify the accuracy of simulated results, experiments are performed. Compared simulated results with experimental ones, good agreement is obtained.