Overview of modelling and simulation of metal powder bed fusion process at Lawrence Livermore National Laboratory

King, W.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.

doi:10.1179/1743284714Y.0000000728

Overview of modelling and simulation of metal powder bed fusion process at Lawrence Livermore National Laboratory

Journal Article · Thu Dec 04 00:00:00 EST 2014 · Materials Science and Technology

DOI:https://doi.org/10.1179/1743284714Y.0000000728· OSTI ID:1502019

King, W.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.

The metal laser powder bed fusion additive manufacturing process uses high power lasers to build parts layer upon layer by melting fine metal powders. Qualification of parts produced using this technology is broadly recognised as a significant challenge. Physics based process models have been identified as being foundational to qualification of additively manufactured metal parts. In the present article, a multiscale modelling strategy is described that will serve as the foundation upon which process control and part qualification can be built. This includes a model at the scale of the powder that simulates single track/single multilayer builds and provides powder bed and melt pool thermal data. A second model computationally builds a complete part and predicts manufactured properties (residual stress, dimensional accuracy) in three dimensions. Finally, modelling is tied to experiment through data mining.

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1502019

Alternate ID(s):: OSTI ID: 1502045

Report Number(s):: LLNL-JRNL-656041; LLNL-JRNL-694040; 822409

Journal Information:: Materials Science and Technology, Journal Name: Materials Science and Technology Journal Issue: 8 Vol. 31; ISSN 0267-0836

Publisher:: Taylor & FrancisCopyright Statement

Country of Publication:: United States

Language:: English

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