Title: Determination of thermal stress distribution in metallic layer during selective laser sintering using finite element method

Authors: Patil Makarand Ramu, Vinod Yadava

Addresses: Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad 211 004, India. ' Department of Mechanical Engineering, Motilal Nehru National Institute of Technology, Allahabad 211 004, India

Abstract: Selective Laser Sintering (SLS) is used to make strong and hard metallic functional components layer by layer directly from several kinds of metallic powders. The high laser power (about 1 kW) during SLS results in high-localised temperature rise (about 1000–1500°C). Thermal stresses are generated due to temperature gradient. The study of thermal stress distribution within the metallic layer is important from the quality of the product point of view. A transient Finite Element Method (FEM)-based 2D temperature and thermal stress model has been developed to calculate the temperature distribution and thermal stress distribution within a single metallic layer formed on the powder bed using SLS. This paper predominantly deals with the effects of laser power and time of scanning on thermal stress distribution within a single layer of Ni-based alloy (82.8 %Ni, 9.5 %Cr, 2%B, 3%Si, 2.3%Fe, 0.4%C) during SLS.

Keywords: rapid prototyping; selective laser sintering; SLS; temperature distribution; thermal stress distribution; finite element method; FEM.

DOI: 10.1504/IJMTM.2008.016777

International Journal of Manufacturing Technology and Management, 2008 Vol.13 No.2/3/4, pp.280 - 296

Published online: 22 Jan 2008 *

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