Numerical simulation of two-dimensional melting and resolidification of a two-component metal powder layer in selective laser sintering process

Selective laser sintering (SLS) of metal powder is an emerging technology by which metal parts can be fabricated in a layer by layer fashion. SLS of the first layer is modeled as melting and resolidification of a metal powder layer subject to a moving heat source on top, while the bottom is adiabatic. SLS of the consecutive layer is modeled as melting and resolidification of a metal powder layer on top of the existing multiple resolidified layers. The results indicate that the thicknesses of the loose metal powder layer, the moving heat source intensity, and the scanning velocity have significant effects on the sintering process in both the first layer and each subsequent layer. A parametric study is performed, and the best combination of processing parameters is recommended.