Multi-Scale Modeling in Additive Manufacturing

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Computation and Simulation on Metals".

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 1788

Special Issue Editor


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Guest Editor
Commonwealth Scientific and Industrial Research Organisation (CSIRO), Data 61, Clayton 3168, Australia
Interests: mathematical modelling; numerical algorithms; SPH; DEM; FEM; finite volume; mesh adaptation; contact mechanics; additive manufacturing; interfacial physics; incompressible flows

Special Issue Information

Dear Colleagues,

Metal additive manufacturing (AM) has brought impressive advances in the manufacture of bespoke parts with complex geometries. However, it also poses many technical barriers due to the highly transient and varying physical phenomena which occur on a broad range of length and time scales difficult to observe and characterize.

The development of fully integrated multi-physics and multi-scale computational models in AM is highly desirable and still a key challenge, with an important requirement in AM modelling being the ability to predict and control the microstructure (and, therefore, the mechanical properties) of the component. However, the microstructure is strongly dependant on thermal history during processing, which in turn results from several independent and diverse physical phenomena interacting at disparate spatial and temporal scales (such as laser heating, powder coating and melt pool dynamics).

This Special Issue aims to contain articles reporting on new and progressive research into multi-scale strategies for metal additive manufacturing, the scope including methods to integrate/link sequential multiple physics-based models, as well as concurrent frameworks to couple micro-scale and macro-scale models.

Dr. Sharen Cummins
Guest Editor

Manuscript Submission Information

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Keywords

  • additive manufacturing
  • multi-scale modelling
  • multi-physics
  • mesh-free methods
  • grid-based methods
  • hybrid models
  • concurrent methods
  • semi-empirical models

Published Papers (1 paper)

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Research

16 pages, 62638 KiB  
Article
Surface Formation of Sloping Features in Laser Powder–Bed Fusion by Multi-Track Multi-Layer Simulations
by Trong-Nhan Le and Kevin Chou
Metals 2023, 13(5), 976; https://doi.org/10.3390/met13050976 - 18 May 2023
Cited by 2 | Viewed by 1439
Abstract
Laser powder–bed fusion (L-PBF) metal additive manufacturing has been widely utilized in various industries. However, large variability and inconsistent quality of the built parts still hinder the full potential of this manufacturing technology. Regarding part quality, the poor surface finish of sloping features [...] Read more.
Laser powder–bed fusion (L-PBF) metal additive manufacturing has been widely utilized in various industries. However, large variability and inconsistent quality of the built parts still hinder the full potential of this manufacturing technology. Regarding part quality, the poor surface finish of sloping features remains one of the major shortcomings of L-PBF. The process parameters and contouring strategies have been identified as the primary factors dictating the surface roughness of the inclined surfaces, both up-skin and down-skin. Experimental approaches to modify the surface roughness by tuning contouring parameters could be costly and time-consuming. In addition, such methods cannot provide adequate physical insights into the phenomenon. Therefore, this study presents a multi-physics modeling framework to simulate a multi-track multi-layer L-PBF process in fabricating an inclined sample. The established simulation provides a valuable physical understanding of the driving forces exacerbating the formation and roughness of the inclined surfaces. The simulation results imply that the voids, formed due to insufficient melting in the low-energy contouring scan, are the leading cause of higher surface roughness for up-skin regions. On the other hand, though the visualization of attached particles is challenging regarding the down-skin surface, the simulated results show a lower and abnormal thermal gradient at the melt boundary due to the poorly supported melt region. The presence of thermal gradient irregularities suggests an overabundance of powder particles adhering to the melt boundary, resulting in increased surface roughness on the down-skin. Full article
(This article belongs to the Special Issue Multi-Scale Modeling in Additive Manufacturing)
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