Analysis of radiation pressure and aerodynamic forces acting on powder grains in powder-based additive manufacturing.

Selection of process parameters is an important step in Powder-Based Additive Manufacturing (PBAM) of metals. In order to achieve an optimal parameter set, current literature is mainly focused on the understanding of powder dynamics by analysing the aerodynamic forces. In this letter, however, we show the importance of the laser induced force (radiation pressure) on the powder dynamics. Generalised Lorenz-Mie theory has been employed to accurately estimate the radiation pressure and it is shown that its magnitude is significant in comparison to various aerodynamic forces and the grains weight, hence, can significantly contribute to denudation and spatter observed in the manufacturing process. Furthermore, the importance of compressibility and rarefaction effects on the magnitude of drag and lift forces that a particle experiences is demonstrated by estimating the Ma and Kn numbers under process conditions, which directly impact the powder dynamics. Unlabelled Image • The significance of the radiation pressure on powder dynamics in AM is demonstrated. • The compressibility and rarefaction effects on the aerodynamic forces are highlighted. • Lorenz-Mie theory is adopted to accurately model the powder-laser interaction. [ABSTRACT FROM AUTHOR]