Modeling of the beam transportation behavior in selective laser transmission sintering the translucent core–shell composite powder

In the paper, selective laser transmission sintering the 2%PF/silica sand core–shell composite powders was studied based on a developed optical model by using a Zemax optical design program. The construction of the powder bed was made by the particle stacking model with the composite particle assumed as a three-component optical system. It showed that simulation results agreed well with the experimental data. A focus point after the first layer particle was produced by the translucent spherical lens of particles and then laser beam was quickly diverged by subsequent particles along the beam transportation path. The occurrence of the vaporization at the focus point had little effect on the whole properties of the sintered sample because of its relatively small size. Since no melting pool was produced in the sintering process owing to the thin polymer binder, the rearrangement of the powder bed was not remarkable which led to a constant porosity of the powder bed before and after laser sintering. Laser transmission sintering of core–shell composite powders was basically “contaction” sintering, where particles near to each other as well as within the beam transportation path had an opportunity to sinter together.

► An optical model was proposed to study the beam transportation behavior in SLTS.
► Simulation results agreed well with experimental measurements.
► The variations of the beam size and the distribution of the power density through the beam path were demonstrated.
► The volume shrinkage of the powder bed was relatively small in the course of laser transmission sintering the core–shell composite powder.
► For laser transmission sintering the core–shell composite powder, the “contaction” sintering was performed.