Physics guided heat source for quantitative prediction of IN718 laser additive manufacturing processes  

作　　者：Abdullah Al Amin Yangfan Li Ye Lu Xiaoyu Xie Zhengtao Gan Satyajit Mojumder Gregory J.Wagner Wing Kam Liu 

机构地区：[1]Department of Mechanical Engineering,Northwestern University,Evanston 60208 IL,USA [2]Department of Mechanical and Aerospace Engineering,University of Dayton,Dayton,OH,USA [3]Department of Mechanical Engineering,University of Maryland,Baltimore County,Baltimore,MD 21250,USA [4]Department of Aerospace&Mechanical Engineering,University of Texas at El Paso,El Paso,TX,USA [5]Theoritical and Applied Mechanics Program,Northwestern University,Evanston 60208 IL,USA

出　　处：《npj Computational Materials》2024年第1期2854-2867,共14页计算材料学(英文)

基　　金：the NIST AM Bench organizing committee for their high-quality experimental datasets and the United States National Science Foundation(NSF)funding under Grant No.CMMI-1934367 and Center for Hierarchical Material Design(CHiMaD).

摘　　要：Challenge 3 of the 2022 NIST additive manufacturing benchmark(AM Bench)experiments asked modelers to submit predictions for solid cooling rate,liquid cooling rate,time above melt,and melt pool geometry for single and multiple track laser powder bed fusion process using moving lasers.An in-house developed Additive Manufacturing Computational Fluid Dynamics code(AM-CFD)combined with a cylindrical heat source is implemented to accurately predict these experiments.Heuristic heat source calibration is proposed relating volumetric energy density(ψ)based on experiments available in the literature.The parameters of the heat source of the computational model are initially calibrated based on a Higher Order Proper Generalized Decomposition-(HOPGD)based surrogate model.The prediction using the calibrated heat source agrees quantitatively with NIST measurements for different process conditions(laser spot diameter,laser power,and scan speed).A scaling law based on keyhole formation is also utilized in calibrating the parameters of the cylindrical heat source and predicting the challenge experiments.In addition,an improvement on the heat source model is proposed to relate the Volumetric Energy Density(VED_(σ))to the melt pool aspect ratio.The model shows further improvement in the prediction of the experimental measurements for the melt pool,including cases at higher VED_(σ).Overall,it is concluded that the appropriate selection of laser heat source parameterization scheme along with the heat source model is crucial in the accurate prediction of melt pool geometry and thermal measurements while bypassing the expensive computational simulations that consider increased physics equations.

关 键 词：prediction SOURCE ADDITIVE 

分 类 号：TG1[金属学及工艺—金属学]