Coupled Finite Element and Phase Field Modeling for Selective Laser Sintering Process of Al₂O₃ Catalyst Supports

Abstract Selective Laser Sintering (SLS) is a pivotal additive manufacturing technology for fabricating complex geometries with high precision. This study investigates the SLS process through finite element method (FEM) and phase-field simulations to optimize process parameters and enhance part quality. The research focuses on two critical phases: 3D printing and post-sintering processing. FEM with material activation modules is employed to model the laser sintering process, analyzing stress distribution and its correlation with laser power and scan speed. Results reveal that laser power significantly influences stress levels, while excessive scan speeds (>5 µm/s) induce instability in stress accumulation. Phase-field simulations of post-sintering highlight the role of diffusion coefficients and gradient energy terms in porosity reduction and microstructural evolution. Higher diffusion coefficients (controlled by temperature) lead to denser structures, whereas gradient energy terms affect sintering kinetics without altering final porosity. The integration of these simulations provides a comprehensive framework for optimizing SLS parameters, minimizing defects, and achieving desired mechanical and microstructural properties in ceramic catalyst supports. This work underscores the importance of controlled laser parameters and sintering conditions in advancing SLS-based manufacturing.