Simulating fast electron beam melting with a parallel thermal free surface lattice Boltzmann method

Ammer, Regina; Markl, Matthias; Ljungblad, U.; Körner, Carolin; Rüde, Ulrich

doi:10.1016/j.camwa.2013.10.001

Cited by 103 publications

(41 citation statements)

References 34 publications

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“…Preheating was modelled as a part of the thermal cycle, occurring as initial conditions before the actual electron beam scanning and melting process. Ammer et al [86,87] focused on the 3D thermal lattice Boltzmann method for the simulation of the EBAM process, having taken into consideration physical and thermal effects such as melt pool, beam absorption, melting and solidification.…”

Section: Electron Beam Processesmentioning

confidence: 99%

Additive manufacturing methods and modelling approaches: a critical review

Bikas

Stavropoulos

Chryssolouris

2015

Int J Adv Manuf Technol

1,174

443

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Additive manufacturing is a technology rapidly expanding on a number of industrial sectors. It provides design freedom and environmental/ecological advantages. It transforms essentially design files to fully functional products. However, it is still hampered by low productivity, poor quality and uncertainty of final part mechanical properties. The root cause of undesired effects lies in the control aspects of the process. Optimization is difficult due to limited modelling approaches. Physical phenomena associated with additive manufacturing processes are complex, including melting/ solidification and vaporization, heat and mass transfer etc. The goal of the current study is to map available additive manufacturing methods based on their process mechanisms, review modelling approaches based on modelling methods and identify research gaps. Later sections of the study review implications for closed-loop control of the process.

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Section: Electron Beam Processesmentioning

confidence: 99%

Additive manufacturing methods and modelling approaches: a critical review

Bikas

Stavropoulos

Chryssolouris

2015

Int J Adv Manuf Technol

1,174

443

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“…The method has been used successfully in the simulation of liquid-gas flows of high viscosity and density ratio. Examples can be found in Ammer et al (2014); Anderl et al (2014); Attar and Körner (2011); Donath et al (2010); Janßen (2010); Janssen et al (2010); N. Thürey (2004; Xing et al (2007a,b), and in Bogner and Rüde (2013); Svec et al (2012) for complex liquid-gas-solid flows. However, no theoretical analysis of the FSLBM is currently available.…”

Section: Motivationmentioning

confidence: 99%

Boundary conditions for free interfaces with the lattice Boltzmann method

Bogner

Ammer

Rüde

2015

Journal of Computational Physics

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In this paper we analyze the boundary treatment of the lattice Boltzmann method (LBM) for simulating 3D flows with free surfaces. The widely used free surface boundary condition of Körner et al. (2005) is shown to be first order accurate. The article presents a new free surface boundary scheme that is suitable for second order accurate simulations based on the LBM. The new method takes into account the free surface position and its orientation with respect to the computational lattice. Numerical experiments confirm the theoretical findings and illustrate the different behavior of the original method and the new method.

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“…We use numerical simulation in order to understand the correlation between scanning strategy, resulting solidification conditions and microstructure. The numerical model (based on the Lattice Boltzmann Method) which we have developed for simulation of powder bed based additive manufacturing processes has been described in several publications [8][9][10][11][12][13][14][15]. The beam melting process is simulated on the powder scale, i.e.…”

Section: Numerical Simulationsmentioning

confidence: 99%

Tailoring the grain structure of IN718 during selective electron beam melting

Körner

Helmer

Bauereiß

et al. 2014

MATEC Web of Conferences

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118

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Abstract. Selective electron beam melting (SEBM) is an additive manufacturing method where complex parts are built from metal powders in layers of about 50 µm. SEBM works under vacuum conditions which results in a perfect protection of the metal alloy. The electron beam is used for heating (about 900 • C building temperature) and selective melting. The high beam velocities allow innovative scanning strategies in order to adapt the local solidification conditions which determine the epitaxial solidification process of IN718. We show how scanning strategies can be used either to produce a columnar grain structure with a high texture in building direction or a complete texture-free fine grained structure. Numerical simulations of the selective melting process are applied to reveal the fundamental mechanisms responsible for the completely different grain structures. In addition the influence of the different grain structures on the mechanical properties of IN718 is briefly discussed.

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Simulating fast electron beam melting with a parallel thermal free surface lattice Boltzmann method

Cited by 103 publications

References 34 publications

Additive manufacturing methods and modelling approaches: a critical review

Additive manufacturing methods and modelling approaches: a critical review

Boundary conditions for free interfaces with the lattice Boltzmann method

Tailoring the grain structure of IN718 during selective electron beam melting

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