Explore the vast range of titles available.

The elasto-plastic material behavior, material strength and failure modes of metals fabricated by additive manufacturing technologies are significantly determined by the underlying process-specific microstructure evolution. In this work a novel physics-based and data-supported phenomenological microstructure model for Ti-6Al-4V is proposed that is suitable for the part-scale simulation of laser powder bed fusion processes. The model predicts spatially homogenized phase fractions of the most relevant microstructural species, namely the stable β -phase, the stable α s -phase as well as the metastable Martensite α m -phase, in a physically consistent manner. In particular, the modeled microstructure evolution, in form of diffusion-based and non-diffusional transformations, is a pure consequence of energy and mobility competitions among the different species, without the need for heuristic transformation criteria as often applied in existing models. The mathematically consistent formulation of the evolution equations in rate form renders the model suitable for the practically relevant scenario of temperature- or time-dependent diffusion coefficients, arbitrary temperature profiles, and multiple coexisting phases. Due to its physically motivated foundation, the proposed model requires only a minimal number of free parameters, which are determined in an inverse identification process considering a broad experimental data basis in form of time-temperature transformation diagrams. Subsequently, the predictive ability of the model is demonstrated by means of continuous cooling transformation diagrams, showing that experimentally observed characteristics such as critical cooling rates emerge naturally from the proposed microstructure model, instead of being enforced as heuristic transformation criteria. Eventually, the proposed model is exploited to predict the microstructure evolution for a realistic selective laser melting application scenario and for the cooling/quenching process of a Ti-6Al-4V cube of practically relevant size. Numerical results confirm experimental observations that Martensite is the dominating microstructure species in regimes of high cooling rates, e.g., due to highly localized heat sources or in near-surface domains, while a proper manipulation of the temperature field, e.g., by preheating the base-plate in selective laser melting, can suppress the formation of this metastable phase.

In this paper, a part-scale simulation study on the effects of bi-directional scanning patterns (BDSP) on residual stress and distortion formation in additively manufactured Nitinol (NiTi) parts is presented. The additive manufacturing technique of focus is powder bed fusion using a laser beam (PBF-LB), and simulation was performed using Ansys Additive Print software. The numerical approach adopted in the simulation was based on the isotropic inherent strain model, due to prohibitive material property requirements and computational limitations of full-fledged part-scale 3D thermomechanical finite element approaches. In this work, reconstructed 2D and 3D thermograms (heat maps) from in situ melt pool thermal radiation data, the predicted residual stresses, and distortions from the simulation study were correlated for PBF-LB processed NiTi samples using selected BDSPs. The distortion and residual stress distribution were found to vary greatly between BDSPs with no laser scan vector rotations per new layer, whereas negligible variations were observed for BDSPs with laser scan vector rotations per new layer. The striking similarities between the reconstructed thermograms of the first few layers and the simulated stress contours of the first lumped layer provide a practical understanding of the temperature gradient mechanism of residual stress formation in PBF-LB processed NiTi. This study provides a qualitative, yet practical insight towards understanding the trends of formation and evolution of residual stress and distortion, due to scanning patterns.

Numerical simulations of a complete laser powder bed fusion (LPBF) additive manufacturing (AM) process are extremely challenging, or even impossible, to achieve without a radical model reduction of the complex physical phenomena occurring during the process. However, even when we adopt a reduced model with simplified physics, the complex geometries of parts usually produced by the LPBF AM processes make this kind of analysis computationally expensive. In fact, small geometrical features—which might be generated when the part is designed following the principle of the so-called design for AM, for instance, by means of topology optimization procedures—often require complex conformal meshes. Immersed boundary methods offer an alternative to deal with this kind of complexity, without requiring complicated meshing strategies. The two-level method lies within this family of numerical methods and presents a flexible tool to deal with multi-scale problems. In this contribution, we apply a modified version of the recently introduced two-level method to part-scale thermal analysis of LPBF manufactured components. We first validate the proposed part-scale model with respect to experimental measurements from the literature. Then, we apply the presented numerical framework to simulate a complete LPBF process of a topologically optimized structure, showing the capability of the method to easily deal with complex geometrical features.

Purpose This study aims to develop a novel thermal modeling strategy to simulate electron beam powder bed fusion at part scale with machine-varying process parameters strategy. Single-bead and part-scale experiments and modeling were studied. Scanning strategies were described by the process controlling functions that enabled modeling. Design/methodology/approach The finite element analysis thermal model was used along with the powder bed fusion with electron beam experiments. The proposed strategy involves dividing a part into smaller sections and creating meso-scale models for each subsection. These meso-scale models take into consideration the variable process parameters, including power and velocity of the moving heat source, during part building. Subsequently, these models are integrated to perform partscale simulations, enabling more realistic predictions of thermal accumulation and resulting distortions. The model was built and validated with single-bead experiments and bulky parts with different features. Findings Single-bead experiments demonstrated an average error rate of 6%–24% for melt pool dimension prediction using the proposed meso-scale models with different scanning control functions. Part-scale simulations for three different geometries (cantilever beams with supports, bulk artifact and topology-optimized transfer arm) showed good agreement between modeled temperature changes and experimental deformation values. Originality/value This study presents a novel approach for electron beam powder bed fusion modeling that leverages meso-scale models to capture the influence of variable process parameters on part quality. This strategy offers improved accuracy for predicting part geometry and identifying potential defects, leading to a more efficient additive manufacturing process.