Simulation of Meltpool Dynamics and Prediction of Component Properties in Electron-Beam Melting of Ti-6Al-4V

Meltpool dynamics in Electron-Beam Melting (EBM) have been widely identified as a key process phenomenon that directly influences the microstructure and quality of the produced components. A CFD model incorporating non-linear heat transfer and material properties has been developed to investigate the meltpool dynamics in EBM of Ti-6Al-4V and to predict the resultant component properties. This modeling approach allows for accurate resolution of process physics while avoiding excessive computational cost or time. Predicted and experimental melt pool topologies are compared for differing process and component conditions. The effects of part geometry and process parameters on solidification rates and other microstructural characteristics are discussed and compared with experimental data.