A Numerical Investigation of the Effect of Processing Conditions on the Melt Pool and Temperature Field in Laser Powder Bed Fusion of Tungsten

  • Srivastava, Ayush (Eindhoven University of Technology)
  • van Dommelen, Hans (Eindhoven University of Technology)
  • Geers, Marc (Eindhoven University of Technology)

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As the demand for clean, reliable energy increases, nuclear fusion emerges as a promising solution. However, current fusion reactors find it difficult to sustain operation for extended durations because the reactions generate extremely high heat loads. These severe thermal stresses, particularly on components such as the divertor, restrict reactor operation to just a few seconds or minutes. In the reactor, the divertor functions as an exhaust for particles and neutrons and experiences heat fluxes in the range of 5-10 MW/m$^2$. The divertor is manufactured from tungsten, a refractory material with an extremely high melting temperature (around 3695 K). Liquid metal divertor component may be produced by using laser powder bed fusion (LPBF), a process recognized for its high geometric precision and tight tolerances. The fabrication of tungsten components by LPBF is a challenging process because of the extreme thermophysical properties of the material. Its very high melting point and low thermal conductivity lead to rapid heat dissipation and, if not carefully controlled, lead to an unstable melt pool. Moreover, tungsten’s high ductile-to-brittle transition temperature makes it highly prone to cracking under the severe thermal gradients of LPBF. In this study, therefore, we focus on the thermal simulation of LPBF using a finite-element-based approach that incorporates temperature- and history-dependent material properties to accurately predict the temperature field and the resulting thermal history. In the LPBF process, the material initially exists as a powder, which typically exhibits lower thermal properties (thermal conductivity and specific heat) than the corresponding solid. This disparity in properties leads to variations in the temperature distribution surrounding the melt pool and in the overall temperature evolution. For multi-track or multi-layer simulations, previously solidified layers are reheated by later laser passes and the material properties are then updated based on a phase state of the material. The thermal conductivity, which is the most important property, is dependent on both the porosity and the temperature. By applying these rules in the thermal analysis, the investigation examines the effect of processing conditions on melt pool formation together with the associated temperature field and thermal gradients.