Computation of Effective Thermal Conductivity of Powders for Selective Laser Sintering Simulations

In this work, a discrete element model (DEM) is developed and implemented in the open source flow solver MFiX to simulate the effective thermal conductivity of powder beds for selective laser sintering (SLS) applications, considering scenarios common in SLS such as thin beds, high temperatures, and degrees of powder consolidation. Random particle packing structures of spherical particles are generated and heat transfer between the particles is calculated. A particle–particle contact conduction model, a particle–fluid–particle conduction model, and a view factor radiation model using ray-tracing for calculation of view factors and assuming optically thick particles are used. A nonlinear solver is used to solve for the particle temperatures that drive the net heat transfer to zero for a steady state solution. The effective thermal conductivity is then calculated from the steady state temperature distribution. Results are compared against previously published experimental measurements for powder beds and good agreement is obtained. Results are developed for the impacts of very high temperatures, finite bed depth, consolidation, Young's modulus, emissivity, gas conductivity, and polydispersity on effective thermal conductivity. Emphasis is placed on uncertainty quantification in the predicted thermal conductivity resulting from uncertain inputs. This allows SLS practitioners to control the inputs to which the thermal response of the process is most sensitive.