Accuracy and performance of phase change and latent heat models in metal additive manufacturing process simulation

This work proposes a thermal finite element model for the simulation of metal powder bed fusion additive manufacturing processes on macroscale with a focus on phase change and latent heat effects. Specifically, two well-known existing schemes for the numerical treatment of phase change and latent heat, namely the apparent capacity and the so-called heat integration scheme, are critically reviewed and compared with respect to numerical efficiency and overall accuracy. Moreover, a novel variant of the heat integration scheme is proposed, which allows for improved efficiency and accuracy as compared to the original method. Eventually, a systematic formulation of phase fraction variables is proposed relying either on temperature- or enthalpy-based interpolation schemes.

[1]  Roland W. Lewis,et al.  An improved algrorithm for heat conduction problems with phase change , 1978 .

[2]  R. M. Ferencz,et al.  Experimental comparison of residual stresses for a thermomechanical model for the simulation of selective laser melting , 2016 .

[3]  Roland W. Lewis,et al.  Finite element solution of non‐linear heat conduction problems with special reference to phase change , 1974 .

[4]  Santiago Badia,et al.  A scalable parallel finite element framework for growing geometries. Application to metal additive manufacturing , 2018, International Journal for Numerical Methods in Engineering.

[5]  David W. Rosen,et al.  Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing , 2009 .

[6]  Karl-Hermann Tacke,et al.  Discretization of the expliclt enthalpy method for planar phase change , 1985 .

[7]  Paul Steinmann,et al.  Macroscopic simulation and experimental measurement of melt pool characteristics in selective electron beam melting of Ti-6Al-4V , 2017 .

[8]  V. Voller,et al.  ERAL SOURCE-BASED METHOD FOR SOLIDIFICATION PHASE CHANGE , 1991 .

[9]  Andrey V. Gusarov,et al.  Model of Radiation and Heat Transfer in Laser-Powder Interaction Zone at Selective Laser Melting , 2009 .

[10]  A. Dewan,et al.  Solidification Modeling: Evolution, Benchmarks, Trends in Handling Turbulence, and Future Directions , 2014, Metallurgical and Materials Transactions B.

[11]  C. Emmelmann,et al.  Additive Manufacturing of Metals , 2016 .

[12]  T. K. Kundra,et al.  Additive Manufacturing Technologies , 2018 .

[13]  T. Childs,et al.  Selective laser sintering (melting) of stainless and tool steel powders: Experiments and modelling , 2005 .

[14]  V. Voller,et al.  A general enthalpy method for modeling solidification processes , 1992 .

[15]  Klaus-Jürgen Bathe,et al.  AN EFFICIENT ALGORITHM FOR ANALYSIS OF NONLINEAR HEAT TRANSFER WITH PHASE CHANGES , 1982 .

[16]  S. Zlotnik,et al.  A Lagrangian–Eulerian finite element algorithm for advection–diffusion–reaction problems with phase change , 2016 .

[17]  Ninggang Shen,et al.  NUMERICAL THERMAL ANALYSIS IN ELECTRON BEAM ADDITIVE MANUFACTURING WITH PREHEATING EFFECTS , 2012 .

[18]  Parametric Thermal FE Analysis on the Laser Power Input and Powder Effective Thermal Conductivity during Selective Laser Melting of SS304L , 2018, Journal of Manufacturing and Materials Processing.

[19]  Jerome Solberg,et al.  Implementation of a thermomechanical model for the simulation of selective laser melting , 2014 .

[20]  S. Argyropoulos,et al.  Mathematical modelling of solidification and melting: a review , 1996 .

[21]  Andreas Menzel,et al.  Towards the simulation of Selective Laser Melting processes via phase transformation models , 2019, Comput. Math. Appl..

[22]  Yu Zou,et al.  Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation , 2017, ArXiv.