Fraunhofer-Institut für Werkstoffmechanik IWM
The laser powder bed fusion process is modelled using six physical simulation steps. The Discrete Element Method (DEM) is used for powder spreading simulations yielding realistic powder beds. Ray tracing (RT) is employed to calculate the laser energy deposition in the material. Smoothed Particle Hydrodynamics (SPH) simulations are then used to study the thermo-viscous flow in the melt pool considering melting and re-solidification, radiation and heat transfer, thermocapillarity and vaporization pressure. Material properties required for predicting the melt pool dynamics are obtained from thermodynamic CALPHAD simulations. The temperature field of the melt pool is coupled to a Cellular Automaton (CA), which calculates the growth of dendritic grains and, thus, provides a prediction for the microstructure formed during solidification. This microstructure serves then as input for Crystal Plasticity Finite Element Method (CP-FEM) simulations to qualitatively describe texture dependent mechanical properties.
Abstract
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