A review on metal additive manufacturing: modeling and application of numerical simulation for heat and mass transfer and microstructure evolution

Abstract

Metal additive manufacturing technology has been widely used in prototyping, parts manufacturing and repairing. Metal additive manufacturing is a multi-scale and multi-physical coupling process with complex physical phenomena of heat and mass transfer and microstructure evolution. It is hard to directly observe the dynamic behavior and microstructure evolution of molten pool during additive manufacturing. Therefore, numerical simulation of additive manufacturing process is significant since it can efficiently and pertinently predict and analyze the physical phenomena in the process of metal additive manufacturing, and provide a reference for technological parameters selection. In this review, the research progress of numerical simulation of metal additive manufacturing is discussed. Various aspects of numerical simulation models are reviewed, including: (1) Introduction of basic control method and physical description of numerical simulation models;(2) Comparison of various heat and mass transfer models based on different physical assumptions (heat conduction model; heat flux coupling model; discrete powder particle heat flux coupling model); (3) Applications of various microstructure evolution models [phase field (PF), cellular automata (CA), and Monte Carlo (MC)]. Finally, the development trend of numerical simulation of metal additive manufacturing, including the thermal-flow-solid coupling model and deep learning for numerical model, is analyzed.

On the current research progress of metallic materials fabricated by laser powder bed fusion process: a review

“…MC is also a model based on minimum grain boundary interface energy. The MC method provides higher calculation efficiency than the CA method but with some drawbacks [179]. The MC technique cannot accurately determine the crystal orientation.…”

“…] have implemented the MC method to predict the microstructural evolution of metal alloys in AM. Jiang et al [179] have provided a comprehensive review of the three models mentioned above and their applications in the numerical simulation of the AM process.…”

Physical manufacturing: the basic theory and technical system

“…Physical behavior quantities are some abstract quantities determined by the physical analysis process, such as structural stiffness matrix and deformation energy in structural deformation, heat exchange coefficient and thermal conductivity, electrical perveance and conductivity, magnetic induction intensity and magnetic flux, etc. (Liu et al. , 2021)…”

“…Physical behavior quantities are some abstract quantities determined by the physical analysis process, such as structural stiffness matrix and deformation energy in structural deformation, heat exchange coefficient and thermal conductivity, electrical perveance and conductivity, magnetic induction intensity and magnetic flux, etc. (Liu et al, 2021) In the product manufacturing process, the physical change process can be described as the field diffusion process. According to different physical analysis theories, these physical processes generally model the physical properties in the part entity for specific physical property quantities, such as the structure deformation caused by the processing process, temperature change caused by heat transfer, excitation current and material magnetization caused by electromagnetic change, etc.…”

The Prediction of Ferrite Ratio in HAZ of EH36 Steel Electro‐Gas Welding Joints Based on Leblond Equation

“…Microscopic models, such as Cellular Automata, [ 6 ] Monte Carlo, [ 7 ] and Phase Field, [ 8–10 ] concentrate on the microstructure morphology evolution process, which brings a heavy computation burden and thus restricts the calculation size. In industrial practice, the microstructure proportion is a greater concern because it directly affects the welding joint performance, while the specific microstructure morphology may be conveniently acquired according to the welding procedure and metallographic observation.…”