Numerical Analysis of the Melt Pool Kinetics in Selective Laser Melting Based Additive Manufacturing of M g2Si Thermoelectric Powders

TR Number
Journal Title
Journal ISSN
Volume Title
Virginia Tech

Thermoelectric generators convert heat energy to electricity and can be used for waste heat recovery, enabling sustainable development. Selective Laser Melting (SLM) based additive manufacturing process is a scalable and flexible method that has shown promising results in manufacturing high ZT Bi2T e3 material and is possible to be extended to other material classes such as M g2Si. The physical phenomena of melting and solidification were investi- gated for SLM-based manufacturing of thermoelectric (M g2Si) powders through comprehen- sive numerical models developed in MATLAB. In this study, Computational Fluid Dynamics (CFD)-based techniques were employed to solve conservation equations, enabling a detailed understanding of thermofluid dynamics, including the temperature evolution and the con- vection currents of the liquid melt within the molten pool. This approach was critical for optimizing processing parameters in our investigation, which were also used for printing the M g2Si powders using SLM. Additionally, a phase field-based model was developed to sim- ulate the directional solidification of the M g2Si in MATLAB. Microstructural parameters like the Secondary and Primary Dendritic Arm Spacing were studied to correlate the effects of processing parameters to the microstructure of M g2Si.

Additive Manufacturing, Computational Fluid Dynamics, Phase Field, Thermoelectrics