Three-dimensional modeling of laser sintering of a two-component metal powder layer on top of sintered layers

A three-dimensional model of selective laser sintering of a two-component loose metal powder layer on top of previously sintered layers by a single-line laser scanning is presented. A temperature-transforming model is employed to model melting and resolidification accompanied by partial shrinkage during laser sintering. The heat losses at the top surface due to natural convection and radiation are taken into account. The liquid flow of the molten low-melting-point metal powders, which is driven by capillary and gravity forces, is also considered and formulated by using Darcy's law. The effects of the dominant processing parameters, such as laser-beam intensity, scanning velocity, and number of the existing sintered layers underneath, are investigated.