Additive Manufacturing in Construction
AMC TRR 277

Project B 01

Networking with other projects

Simulation of the Selective Laser Melting (SLM) Process for the Additive Manufacturing of Steel Parts

Laser powder bed fusion (LPBF) is a process involving several length scales, fluid and solid mechanics. Project B01 provides a model and related computational framework for simulation of the LPBF process, from the micro-scale (powder bed) to the meso- scale (mm range). To that end, local melting, flow and solidification are simulated using the lattice Boltzmann method (LBM), considering more and more physical phenomena. With the aim of residual stress prediction in the solidified part, numerical simulation possibilities of the equations of solid mechanics using LBM are explored. Upscaling of the high fidelity model results can be used to obtain effective material properties and state of material for use in macroscopic simulations.

Objective

Predictive simulation capabilities of the laser powder-bed fusion process

  • High fidelity thermo- and hydrodynamic melt pool model
  • Residual stress prediction in solidified part

Methods

Development of a mathematical model of the complex multi-physics phenomena and numerical implementation using LBM

  • Mechanically and thermodynamically consistent model development on the particle and mesoscopic scale of the process
  • Numerical discretization of the governing equations using the LBM and phase field formulation for the multiphase thermal flow problem in the melt pool
  • Explorative investigation of solid mechanics simulation possibilities within the lattice Boltzmann framework

Networking with other projects

  • Experimental validation A06
  • Effective properties for C01
  • Shared code framework with B03

Project leaders

Prof. Dr. Laura De Lorenzis

Contributors

M. Sc. Oliver Boolakee Dr. Roland Kruse