Physics-Based Modeling and Predictive Simulation of Powder Bed Fusion Additive Manufacturing Across Length Scales

  title={Physics-Based Modeling and Predictive Simulation of Powder Bed Fusion Additive Manufacturing Across Length Scales},
  author={Christoph Meier and Sebastian L. Fuchs and Nils Much and Jonas Nitzler and Ryan W. Penny and Patrick M. Praegla and Sebastian Pr{\"o}ll and Yushen Sun and Reimar Weissbach and Magdalena Schreter and Neil Eugene Hodge and A. John Hart and Wolfgang A. Wall},
1Institute for Computational Mechanics, Technical University of Munich, Munich, Germany 2Institute for Continuum and Material Mechanics, Hamburg University of Technology, Hamburg, Germany 3Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, USA 4Unit of Strength of Materials and Structural Analysis, University of Innsbruck, Innsbruck, Austria 5Methods Development Group, Lawrence Livermore National Laboratory, Livermore, USA 
3 Citations
A simple yet consistent constitutive law and mortar-based layer coupling schemes for thermomechanical macroscale simulations of metal additive manufacturing processes
A coupled thermomechanical finite element model tailored to the macroscale simulation of metal additive manufacturing processes such as selective laser melting and the derivation of a consistent constitutive law on basis of a Voigt-type spatial homogenization procedure is proposed. Expand
Three-dimensional numerical simulation of selective laser melting process based on SPH method
  • Yunji Qiu, Xiaofeng Niu, Tingting Song, Mengqing Shen, Wenqi Li, Wenliang Xu
  • Materials Science
  • Journal of Manufacturing Processes
  • 2021
Abstract Selective laser melting (SLM) is an advanced, efficient and capable manufacturing technology that utilizes a laser for heating metal or alloy powders to melt and solidify directly into metalExpand


Simulation of additive manufacturing using coupled constitutive and microstructure models
Abstract The paper describes the application of modeling approaches used in Computational Welding Mechanics (CWM) applicable for simulating Additive Manufacturing (AM). It focuses on theExpand
Experimental comparison of residual stresses for a thermomechanical model for the simulation of selective laser melting
Abstract Selective laser melting (SLM) is an additive manufacturing process in which multiple, successive layers of metal powders are heated via laser in order to build a part. Modeling of SLMExpand
Numerical simulation of Laser Fusion Additive Manufacturing processes using the SPH method
Abstract In this work, the Smooth Particle Hydrodynamics (SPH) method, a Lagrangian mesh-free numerical scheme, is adapted for the first time to resolve thermal–mechanical–material fields in a rangeExpand
Mesoscopic Simulation of Heat Transfer and Fluid Flow in Laser Powder Bed Additive Manufacturing
Laser-powder bed fusion (L-PBF) additive manufacturing involves complex physics such as heat transfer and molten metal flow, which have a significant influence on the final build quality. In thisExpand
Accurate Prediction of Melt Pool Shapes in Laser Powder Bed Fusion by the Non-Linear Temperature Equation Including Phase Changes
A physical model based on a transient temperature equation (including latent heat), w.r.t. the experimental set AMB2018-02 provided within the additive manufacturing benchmark series is validated and anisotropic conductivity is introduced, intended to be a simplistic model for heat material convection inside the melt pool. Expand
Three dimensional Monte Carlo simulation of grain growth during GTA welding of titanium
The work reported here represents significant advancement in the modeling of grain structure evolution in metallic systems. Utilizing computed temperature fields from a well tested heat transfer andExpand
Implementation of a thermomechanical model for the simulation of selective laser melting
The present work describes continuum modeling of SLM as envisioned for eventual support of part-scale modeling of this fabrication process to determine end-state information such as residual stresses and distortion. Expand
Consistent thermo-mechano-metallurgical model of welded steel with unified approach to derivation of phase evolution laws and transformation-induced plasticity
Coupled electromagnetic, thermal, mechanical, and metallurgical processes occur in the heat affected zone (HAZ) during welding. Metallurgical processes: melting, solidification and solid phaseExpand
Towards improved speed and accuracy of laser powder bed fusion simulations via multiscale spatial representations
Results from higher resolution simulations of the implementation of an AMR algorithm within a multiphysics, parallelized finite element code, and its application to the LPBF problem show that while AMR is a necessary component for increased accuracy in a computationally efficient manner, other improvements are also necessary, including handling of the multiple time scales inherent to the problem. Expand
Phase-Field Modeling of Microstructure Evolution in Electron Beam Additive Manufacturing
In this study, the microstructure evolution in the powder-bed electron beam additive manufacturing (EBAM) process is studied using phase-field modeling. In essence, EBAM involves a rapidExpand