The selective laser melting (SLM) process is a promising AM technique that enables the rapid
production of prototypes and lately weight-sensitive/multi-functional parts at small volumes, with
almost arbitrary complexity. The process builds the final parts layer-upon-layer by going through three
main stages during each cycle: (1) deposition of a layer of fine powder (Dp≈30 μm) on a fabrication
surface to form a powder bed (~50 μm thick); (2) laser heating at specific locations; (3) fusion of the
powder grains through melting and solidification.
However, various complex and interacting heat transfer and phase change processes are not fully understood resulting in relatively low technology readiness levels despite substantial advantages of the technology, such as the production of complex parts, mass customization, and on-demand manufacturing.
Objectives and the research plan. This project aims to deliver a new modelling approach for the SLM process. To achieve this the student will contribute to the development of a state-of-the-art high-fidelity computational framework (fully resolved Discerete Element-lattice Boltzmann) for large scale simulation of powder spreading, heat transfer and phase changes during the SLM process. The student will contribute to the theoretical model development and will include them in our high-fidelity computational framework to provide new insight into the process using numerical experiments.
Dr Sina Haeri
Minimum entry qualification - an Honours degree at 2:1 or above (or International equivalent) in a relevant science or engineering discipline, possibly supported by an MSc Degree. Further information on English language requirements for EU/Overseas applicants.
Tuition fees + stipend are available for Home/EU students (International students can apply, but the funding only covers the Home/EU fee rate)