LAUSR

Purpose This paper aims to study the effect of processing parameters and the fundamental mechanism of surface morphologies during electron beam selective melting. Design/methodology/approach From the powder-scale level, first, the discrete element method is used to obtain the powder bed distribution that is comparable with the practical condition; then, the finite volume method is used to simulate the particle melting and flowing process. A physically reliable energy distribution of the electron beam is applied and the volume of fluid method is coupled to capture the free boundary flow. Twelve sets of parameters grouped into three categories are examined, focusing on the effect of scan speed, input powder and energy density. Findings According to the results, both melting pool width and depth have a positive relation with the energy density, whereas the melting pool length is insensitive to the scan velocity change. The balling effect is attributed to either an insufficient energy input or the flow instability; the hump effect originates from the mismatch between electron beam moving and the fluid flow. The scan speed is a key parameter closely related to melting pool size and surface morphologies. Originality/value Through a number of case studies, this paper gives a comprehensive insight of the parameter effects and mechanisms of different surface morphologies, which helps to better control the manufacturing quality of electron beam selective melting.