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Abstract
Metal additive manufacturing techniques such as SLM, and DMLS, based on the powder bed fusion (PBF) process, rely on a high-quality powder bed to minimize the formation of defects in the manufactured part. Various parameters like blade velocity, the thickness of the powder layer, shape and size of particles, angle of repose, coefficient of friction, and restitution are known to influence the bed quality. However, there is limited information available on the effect of moisture on powder bed quality.The purpose of this study is to simulate the powder spreading process considering the interactions between individual particles in the presence of moisture using a 3D discrete element method (DEM) model to evaluate the effect of particle moisture on powder bed quality. The commercial DEM software package EDEM along with the Mikami liquid bridge contact model and the Hertz-Mindlin contact model are used for the simulations. In addition, the combined effects of the gas-particle interaction forces on the spreading process of moisturized particles generated due to shield gas flow are simulated using a four-way CFD-DEM coupling. EDEM-OpenFOAM coupling is utilized for this purpose. The quality of the powder bed is measured in terms of void fraction, mass flow rate, surface roughness, and particle agglomeration. The results obtained show an increase in void fraction and surface roughness of the powder bed, indicating a degradation of the powder bed quality. The shield gas flow helps in reducing the void fraction of the moisturized powder bed. The average mass flow rate, agglomeration, and stress distribution results demonstrate that particles form aggregates due to moisture which may lead to jamming.