A Meshless Method of Radial Basis Function-Finite Difference Approach to 3-Dimensional Numerical Simulation on Selective Laser Melting Process

Selective laser melting (SLM) is a rapidly evolving technology that requires extensive knowledge and management for broader industrial adoption due to the complexity of phenomena involved. The selection of parameters and numerical analysis for the SLM process are both costly and time-consuming. In this paper, a three-dimensional radial basis function-finite difference (RBF-FD) meshless model is introduced to accurately and efficiently simulate the molten pool size and temperature distribution during the SLM process for austenitic stainless steel (AISI 316L). Two different volumetric moving heat source models were presented, namely the ray-tracing method heat source model and the double-ellipsoidal shape heat source model. The temperature-dependent material properties and phase change process were also considered, based on experiments and effective models. Results of the model for the molten pool size were validated with those of the literature. The proposed approach can be used to predict the effect of different laser power and scan speed on the molten pool size and temperature gradient along the depth direction. The result reveals that the depth of the molten pool is more sensitive to laser power than scan speed. Under the same scan speed, a 22% change in laser power (45 +/- 10 W) affects the maximum temperature proportionally by about 9%. The developed algorithm is computationally efficient and suitable for industrial applications.