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

相加制造(AM)技术由于其适应性和通用性，近年来吸引了许多行业的关注。AM正在改变工程设计和制造中的思想流派，一个新的“为设计制造”的范例正在形成，取而代之的是“为制造而设计”的方法。不管AM技术的无可争议的特点如何，金属AM的广泛采用一直受到与生产部件的验证和认证相关的问题的阻碍，这主要是由于AM过程对环境和材料干扰的依赖。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进行彻底建模，以获得最佳工艺参数，而无需进行大量的实验试错。 本研究项目的主要目的是建立一个高保真的有限元模型来确定高温合金(镍基合金)粉末床激光熔化过程中的熔池动力学和熔池形状。西门子加拿大公司有一个正在进行的AM工艺模拟项目，该项目要求熔珠的精确特征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，同时通过该项目产生的数据将被馈送到当前的工艺模拟中，以提高其精度和可靠性。 拟议的研究将分4个阶段进行。(1)将图形处理器添加到当前的计算设置；(2)模型开发；(3)使用可用实验数据进行模型验证；以及(4)从模型中为西门子应用程序提取数据。 这一结果将加强西门子正在采取的AM认证前进战略，从而提高生产率和产品质量。这可以让加拿大在地图上成为这一发展的发源地。

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.