Modelling and analysis of process-induced properties of structures additively manufactured by laser surface cladding

增材制造（AM）技术正在成为生产几乎任意复杂部件和工件的最有前途的方法之一。与减法制造工艺相反，增材制造的特点是材料是一层一层地添加到组件中。相对于标准工艺的优势，特别是在航空航天和汽车工业中所谓的“快速模具”或生物医学工程中，增材制造在制造特殊和定制零件和轻质结构方面几乎是不可或缺的。该项目的总体目标是模拟使用激光粉末熔覆（LPAS）的部件制造，以准确预测增材制造部件的最终轮廓以及工艺引起的残余应力，并研究所选工艺参数和扫描策略的影响。模拟的基础是热力学一致和基于微观力学的材料模型，该模型提供了物理上可信的结果和数据。除此之外，物理上的合理性使新方法可以应用于没有或有限的实验数据可以与模拟相匹配的问题。基于数据的方法和算法的结合还可以实现精度和计算速度之间的最佳权衡，这是经典方法无法实现的。

Additive manufacturing (AM) technologies are emerging as one of the most promising methods for the production of almost arbitrarily complex components and workpieces. In contrast to subtractive manufacturing processes, AM is characterized by the fact that material is specifically added to the component layer by layer. The advantages over standard processes have ensured, particularly in the aerospace and automotive industries for so-called "rapid tooling" or in biomedical engineering, that AM appears to be almost indispensable in the manufacture of special and customized parts and lightweight constructions.The overall goal of this project is to simulate the fabrication of components using laser powder cladding (LPAS) to accurately predict the final contour of the additively manufactured component as well as the process-induced residual stresses and to investigate the influences of the selected process parameters and scan strategy. The basis of the simulations is a thermodynamically consistent and micromechanics-based material model, which provides physically plausible results and data. Among other things, the physical plausibility allows the new methodology to be applied to problems in which no or limited experimental data are available to match the simulations. The incorporation of data-based methods and algorithms also enables an optimal trade-off between accuracy and computational speed, which would be impossible to achieve with classical methods.