Modeling and simulation of multi-material manufacturing of metals in powder bed fusion additive manufacturing

粉末床熔融增材制造技术为生产由高性能材料制成的复杂零件提供了机会。此外，这些技术有可能通过新的粉末输送机制同时处理不同的材料。这为局部调整的材料组合开辟了新的优化前景，而这是传统技术难以生产的。 该建议旨在分析和物理建模的影响，在多材料制造的特殊工艺条件下的粉末床融合。建立了一个热力学一致性模型，该模型包括不同材料的熔化行为、对流和扩散混合以及冷却和凝固。该模型将被集成到一个软件中，该软件是在我们研究所过去十年中开发的。该模型将通过不同粉末混合物的增材制造样品进行实验验证。在项目结束时，该软件应在粉末床熔融工艺的多材料制造过程中对主要机制进行建模，并支持为致密和均匀制造开发合适的工艺策略。

Powder bed fusion additive manufacturing technologies offer the opportunity to produce complex parts made of high performance materials. Additionally, these technologies have the potential to process different materials by new powder delivery mechanisms at once. This opens new optimization perspectives of locally adjusted material combinations which are hardly producible with conventional technologies. This proposal aims to analyze and physically model the effects during multi-material manufacturing under the special process conditions of powder bed fusion. A thermodynamic consistent model will be developed, which includes the melting behavior of different materials, the convective and diffusive mixing as well as cooling and solidification. This model will be integrated into a software, which has been developed during the last decade at our institute. The model will be experimentally verified by additively manufactured samples of different powder mixtures. At the end of the project, the software should model the main mechanisms during multi-material manufacturing of powder bed fusion processes and support the development of suitable process strategies for a dense and homogenous manufacturing.