Rapid Simulation of Laser Processing of Discrete Particulate Materials

The objective of this paper is to develop a computational model and corresponding solution algorithm to enable rapid simulation of laser processing and subsequent targeted zonal heating of materials composed of packed, discrete, particles. Because of the complex microstructure, containing gaps and interfaces, this type of system is extremely difficult to simulate using continuum-based methods, such as the Finite Difference Time Domain Method or the Finite Element Method. The computationally-amenable model that is developed captures the primary physical events, such as reflection and absorption of optical energy, conversion into heat, thermal conduction through the microstructure and possible phase transformations. Specifically, the features of the computational model are (1) a discretization of a concentrated laser beam into rays, (2) a discrete element representation of the particulate material microstructure and (3) a discrete element transient heat transfer model that accounts for optical (laser) energy propagation (reflection and absorption), its conversion into heat, the subsequent conduction of heat and phase transformations involving possible melting and vaporization. A discrete ray-tracking algorithm is developed, along with an embedded, staggered, iterative solution scheme, which is needed to calculate the optical-to-thermal conversion, particle-to-particle conduction and phase-transformations, implicitly. Numerical examples are given, focusing on concentrated laser beams and the effects of surrounding material conductivity, which draws heat away from the laser contact zone, thus affecting the targeted material state.