arXiv subjects

Rakibul Islam Kanak

Publications and source records attributed to Rakibul Islam Kanak.

2 recordsLinked to original sources

arXiv2026

Laser Powder Bed Fusion Melt Pool Dynamics for Different Geometric Variations and Powder Layer Heights: High-Fidelity Multiphysics Modeling vs 2025 NIST Experiments

Metal Laser Powder Bed Fusion (PBF-LB/M) is a leading additive manufacturing technique in which part quality and grain morphology are highly dependent on process parameters. Numerous studies of process variations, such as laser power, scan speed, and spot diameter, have demonstrated that they strongly influence melt pool dynamics; however, the effects of powder layer height and geometric variations remain less well understood. In this article, we focus on variations in powder layer height and part geometry to study their influence on melt pool dynamics. We employed a high-fidelity multiphysics simulation framework based on the open source finite volume method (FVM) solver package `LaserBeamFoam' built on `OpenFOAM' to study the variations in different melt pool metrics -- melt pool depth, width, bead height, overlap depth, overlap width, solidified area, and dilution area. The solver captures coupled phenomena of heat transfer, fluid flow, vaporization, recoil pressure, Marangoni convection, and realistic laser reflection behavior to accurately model the melt pool dynamics. Simulations are performed for different powder layer heights and geometric dimensions for direct comparison with benchmark experiments conducted at the National Institute of Standards and Technology (NIST) in 2025. Quantitative validation against NIST experiment demonstrates excellent agreement in all the melt pool metrics. These results highlight the predictive capability of physics-based PBF-LB models, paving the way for process optimization, defect mitigation, and the integration of simulation into digital twin frameworks for additive manufacturing.

physics.app-ph↗

arXiv2025

Process Microstructure Coupling in Reduced Gravity Laser Welding via Open-Source Multiphysics Simulation Framework

Supplying spare parts from Earth for in space repair is economically prohibitive and logistically slow, posing a major barrier to sustainable space operations. As lunar and Martian missions accelerate in the coming decades, the feasibility of in-situ repair methods, particularly laser based welding, must be rigorously evaluated. The micro scale physics governing weld quality are fundamentally altered by variations in gravity and ambient pressure, yet their coupled influence across different welding regimes remains poorly understood. This work introduces a fully open-source thermo-fluid-microstructure modeling framework with computational fluid dynamics (CFD) and cellular automata (CA) to quantify how gravitational conditions reshape weld pool behavior across multiple welding regimes and spatial scales. The framework further enables prediction of the resulting microstructure from imposed process parameters, providing an accessible pathway for future research in in space manufacturing (ISM). As a demonstration, the article analyzes laser welding of Al6061 across three process regimes (conduction, transition, and keyhole) and four gravitational environments (Earth, Moon, Mars, and International Space Station (ISS)). Analysis reveals that reduced gravity suppresses buoyancy-driven convection, thereby altering melt pool geometries. Vacuum conditions increase laser energy deposition, while microgravity promotes equiaxed grain formation via reduced melt convection. The framework captures keyhole dynamics, thermal histories, and grain morphologies with high fidelity, validated against experimental data. These findings establish process microstructure relationships critical for reliable metallic fabrication in space and provide a reproducible platform for future in-space manufacturing research.

physics.flu-dyn↗