Thermal modeling of laser sintering of two-component metal powder on top of sintered layers via multi-line scanning

Laser sintering of a two-component metal powder layer on top of sintered layers, with a moving circular Gaussian laser beam is modeled numerically. The overlap between the adjacent scanning lines, as well as the binding between the newly sintered layer and existing sintered layers underneath through melting, are also considered. The governing equation is formulated by a temperature-transforming model, with partial shrinkage induced by melting taken into account. The liquid flow of the molten low melting point metal powders driving by capillary and gravity forces is formulated by Darcy's law. The effects of the dominant processing parameters, including the moving laser beam intensity, scanning speed, and the number of the existing sintered layers underneath on the shape of the heat affected zone (HAZ) are investigated.