Numerical Modeling of the Additive Manufacturing (AM) Processes of Titanium Alloy

Numerical Modeling of Metal-Based Additive Manufacturing Using Level Set Methods

“…Physical phenomena, such as the heat transfer in solid, heat absorption from the heat source, or heat radiation between solid with the surrounding gas, have been successfully simulated [7,8]. Fan and Liou [9] simulated the AM process of titanium alloy and compared the simulation results with experiment, which showed a good agreement. However, some phenomena are not well captured in current computational models due to the complexity of physics, for instance, the Marangoni convection due to surface tension gradients, the motion of liquid, and the radiation losses at the fluid/gas interface.…”

“…One way to model this is to simulate the solid-liquid interface at small scale. This approach is straightforward, but demands a lot of computing resources, so it only applies to small domains (0.1 lm to 10 mm) [9]. For the macroscopic transport problem, the representative elementary volume (REV) is introduced in dealing with the size difference between the fully solid or liquid region and the mushy zone.…”

“…The molten metal flow in the AM processes is a free-surface flow, which means the viscous stresses in the molten metal flow are assumed to be zero. Both the Lagrangian method and the Eulerian method have been applied to model the shape of the freesurface flow [9]. However, the Lagrangian method becomes more difficult in dealing with fluid problems with topological changes.…”

“…The Eulerian method is more suitable to handle moving boundary problems. For instance, the Eulerian method can be used in modeling the powder-based AM process for tracking the mergers and splits at the interface of the melt pool [9].…”

A novel numerical framework for simulation of multiscale spatio-temporally non-linear systems in additive manufacturing processes.

“…The geometry of the problem is a solid base plate of 165 thickness 25.4 mm and a powder layer of thickness 30 µm. The temperature dependent non-linearity in thermal parameters is the same as that of a bulk Ti6Al4V material [159] undergoing metal laser sintering.…”