Modeling the Interface of Aluminum Alloys in Selective Laser Melting

Hybrid additive manufacturing represents a novel approach in the industry, particularly for applications related to repair and maintenance. Discussion on the microstructural and physical attributes of hybrid bi-materials is centered around solidification and diffusion. Throughout the selective laser melting (SLM) process, the microstructure of the printed material experiences dynamic changes. The mechanical properties of the final product are intricately linked to the evolution of grain microstructure, a process heavily influenced by key parameters including scan velocity, laser power, and scan strategy, particularly at the interface. These parameters significantly affect the thermal history and the rate of temperature change during manufacturing. In this research, an advanced finite element (FE), multilayer model has been specifically tailored for AlSi10Mg alloy on cast Aluminum 2000 series within the SLM framework. The primary goal is to forecast thermal profiles and predict the geometric characteristics of the melt pool and the rates of solidification at the interface.