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A multiscale nonequilibrium model for melting of metal powder bed subjected to constant heat flux

A multiscale numerical model based on nonequilibrium thermal effect for melting of metal powder bed subjected to constant heat flux is developed. The volume shrinkage due to density change is taken into account. The nonequilibrium model is discretized by an implicit finite difference method and solved numerically using an iterative tri-diagonal matrix algorithm. The evolutions of powder bed surface temperature and various interfacial locations as well as the melting temperature range during the melting process are investigated. The results show that liquid region, upper and lower parts of mushy zone are formed on the top of unsintered zone as the melting progresses. The duration of the preheating stage shortens and the melting rate accelerates as the initial porosity or initial temperature increases while particle size has much less effect on the melting process. The parametric study shows the melting temperature range of the powder bed widens with increasing initial porosity, decreasing initial temperature or increasing particle size.