Analysis of Laser Powder Bed Fusion (LPBF) Using Computational Fluid Dynamics (CFD)

The metal additive manufacturing technique, Laser Powder Bed Fusion (LPBF), produces complex, precise components through widespread adoption. The process is substantially affected by gas flow dynamics that control both spatter removal, thermal distribution, and part quality. The research uses Computational Fluid Dynamics (CFD) simulations to analyse how bypass systems, nozzle configurations, and suction pressures affect LPBF chamber gas flow optimisation. The ANSYS Fluent software performed a comprehensive numerical evaluation to analyse velocity fields and pressure distributions and streamline patterns across different operational conditions. Implementing bypass systems leads to stabilised flow patterns by reducing recirculation zones and creating uniformity, enhancing melt pool consistency. Implementing optimised nozzles enhances flow efficiency by reducing turbulence while improving spatter ejection. The variation of suction pressure had a moderate effect on velocity distribution, but it proved essential for controlling chamber pressure and gas flow rate. The Coanda effect was observed to influence gas adherence to chamber surfaces, affecting thermal management. The research delivers necessary technical knowledge about LPBF gas flow system optimisation, leading to better manufacturing precision, reduced defects, and increased process dependability.