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高性能材料制成的复杂部件提供了机会。此外，这些技术有潜力通过新的粉末输送机制一次加工不同的材料。这为局部调整的材料组合开辟了新的优化前景，这些材料组合很难用传统技术生产。本文旨在分析和物理模拟在粉末床熔合的特殊工艺条件下多材料制造的影响。将建立一个热力学一致的模型，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。这个模型将被集成到一个软件中，这个软件是我们研究所在过去十年中开发出来的。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，该软件应模拟粉末床融合过程中多材料制造的主要机制，并支持为致密和同质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.