Modeling of melt pool dynamics during powder-bed laser metal additive manufacturing

粉末床激光金属增材制造过程中熔池动力学的建模

• 批准号: 488678-2015
• 负责人: Toyserkani, Ehsan
• 金额: $ 1.82万
• 依托单位: University of Waterloo
• 依托单位国家: 加拿大
• 项目类别: Engage Grants Program
• 财政年份: 2015
• 资助国家: 加拿大
• 起止时间: 2015-01-01 至 2016-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=586363
• 关键词: Modeling; melt; pool; dynamics; during

Additive manufacturing (AM) technologies have attracted many industries in the recent years due to their adaptability and versatility. AM is changing the school of thought in engineering design and manufacturing such that a new "manufacture for design" paradigm is forming to be replaced with the "design for manufacturing" approach. Regardless of undisputable features of AM technologies, the wide adoption of metal AM has been hurdled by the issues associated with the validation and certification of the produced parts, mainly due to the dependencies of the AM processes to environmental and material disturbances. One of the tools that can significantly ease the certification of AM processes and AM-made components is a thorough modeling of AM to obtain optimum process parameters without massive experimental trial-and-error. The main objective of this research project is to develop a high fidelity finite element model to determine the melt pool dynamics and shape during the powder-bed laser metal AM of supper-alloy (nickel-based alloy). Siemens Canada has an ongoing AM process simulation project which requires the precise features of melting bead to be able to effectively determine the thermal maps, residual stresses and distortion. The outcome of this research will help Siemens to adjust its modeling codes while the data generated through this project will be fed to the current process simulation to improve its precision and reliability. The proposed research will be carried out in 4 stages. (1) Adding GPUs to the current computing setup; (2) Model development; (3) Model validation using available experimental data; and, 4) Data extraction from the model for the Siemens application. The outcome will enhance the AM certification path forward strategies that are being taken by Siemens, thus promoting productivity and products quality. This can put Canada on the map as the origin of this development.

近年来，增材制造（AM）技术由于其适应性和多功能性而吸引了许多行业。AM正在改变工程设计和制造的思想流派，一个新的“为设计而制造”的范式正在形成，以取代“为制造而设计”的方法。尽管增材制造技术具有无可争议的特点，但金属增材制造的广泛采用受到与所生产零件的验证和认证相关的问题的阻碍，这主要是由于增材制造工艺对环境和材料干扰的依赖性。可以显著简化AM工艺和AM制造组件认证的工具之一是对AM进行全面建模，以获得最佳工艺参数，而无需大量的实验试错。 本研究的主要目的是开发一个高保真度的有限元模型，以确定熔池的动力学和形状在粉末床激光金属AM的超级合金（镍基合金）。西门子加拿大有一个正在进行的AM工艺模拟项目，该项目需要熔珠的精确特征，以便能够有效地确定热图、残余应力和变形。这项研究的结果将帮助西门子调整其建模代码，而通过该项目生成的数据将被输入到当前的过程模拟中，以提高其精度和可靠性。 研究将分4个阶段进行。(1)将GPU添加到当前的计算设置中;（2）模型开发;（3）使用可用的实验数据进行模型验证;以及，4）从西门子应用程序的模型中提取数据。 其结果将加强西门子正在采取的AM认证战略，从而提高生产力和产品质量。这可以把加拿大作为这一发展的起源。