A review of computational modeling in powder-based additive manufacturing for metallic part qualification

Additive manufacturing (AM) is revolutionizing the manufacturing industry due to several advantages and capabilities, including use of rapid prototyping, fabrication of complex geometries, reduction of product development cycles and minimization of material waste. As metal AM becomes increasingly popular for aerospace and defense original equipment manufacturers (OEMs), a major barrier that remains is rapid qualification of components. Several potential defects (such as porosity, residual stress and microstructural inhomogeneity) occur during layer-by-layer processing. Current methods to qualify AM parts heavily rely on experimental testing, which is economically inefficient and technically insufficient to comprehensively evaluate components. Approaches for high fidelity qualification of AM parts are necessary.,This review summarizes the existing powder-based fusion computational models and their feasibility in AM processes through discrete aspects, including process and microstructure modeling.,Current progresses and challenges in high fidelity modeling of AM processes are presented.,Potential opportunities are discussed toward high-level assurance of AM component quality through a comprehensive computational tool.

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

[2]  L. Shaw,et al.  Thermal and mechanical finite element modeling of laser forming from metal and ceramic powders , 2004 .

[3]  Sergei I. Anisimov,et al.  Vaporization of Metal Absorbing Laser Radiation , 1968 .

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

[5]  J. Mazumder,et al.  Modeling of laser keyhole welding: Part I. mathematical modeling, numerical methodology, role of recoil pressure, multiple reflections, and free surface evolution , 2002 .

[6]  Q. Pei,et al.  Erratum to: Modeling the Microstructure Evolution During Additive Manufacturing of Ti6Al4V: A Comparison Between Electron Beam Melting and Selective Laser Melting , 2016 .

[7]  Bo Cheng,et al.  On Process Temperature in Powder-Bed Electron Beam Additive Manufacturing: Model Development and Validation , 2014 .

[8]  C D Boley,et al.  Metal powder absorptivity: modeling and experiment. , 2016, Applied optics.

[9]  Pulak M. Pandey,et al.  Statistical modelling and optimization of surface roughness in the selective laser sintering process , 2007 .

[10]  C. Körner,et al.  Simulation of grain structure evolution during powder bed based additive manufacturing , 2017 .

[11]  Wilfried Kurz,et al.  Theory of Microstructural Development during Rapid Solidification , 1986 .

[12]  R. Leach,et al.  Industrial survey of ISO surface texture parameters , 2017 .

[13]  J. M. Vitek,et al.  Correlation between solidification parameters and weld microstructures , 1989 .

[14]  Frank W. Liou,et al.  Probabilistic Simulation of Solidification Microstructure Evolution During Laser-based Metal Deposition , 2013 .

[15]  E. Reutzel,et al.  Thermo-mechanical model development and validation of directed energy deposition additive manufacturing of Ti–6Al–4V , 2015 .

[16]  Richard M. Everson,et al.  Finite element simulation of the temperature and stress fields in single layers built without-support in selective laser melting , 2013 .

[17]  Jean-Pierre Kruth,et al.  New Ferro Powder for Selective Laser Sintering of Dense Parts , 2003 .

[18]  Christ Glorieux,et al.  Photopyroelectric measurement of thermal conductivity of metallic powders , 2005 .

[19]  Michael F. Zäh,et al.  Investigations on residual stresses and deformations in selective laser melting , 2010, Prod. Eng..

[20]  Efficient multiscale prediction of cantilever distortion by selective laser melting , 2016 .

[21]  Mohammad Sheikh,et al.  Numerical analysis of the effects of non-conventional laser beam geometries during laser melting of metallic materials , 2007 .

[22]  Ranadip Acharya,et al.  Prediction of microstructure in laser powder bed fusion process , 2017 .

[23]  Judith A. Todd,et al.  Absorption of laser irradiation in a porous powder layer , 2007 .

[24]  Yuwen Zhang,et al.  NUMERICAL SIMULATION OF TWO-DIMENSIONAL MELTING AND RESOLIDIFICATION OF A TWO-COMPONENT METAL POWDER LAYER IN SELECTIVE LASER SINTERING PROCESS , 2004 .

[25]  J. W. Barlow,et al.  Measurement and Prediction of the Thermal Conductivity of Powders at High Temperatures , 1994 .

[26]  S. Ahzi,et al.  Three-dimensional transient finite element analysis of the selective laser sintering process , 2009 .

[27]  T. DebRoy,et al.  Three dimensional Monte Carlo simulation of grain growth during GTA welding of titanium , 2000 .

[28]  Yuebin Guo,et al.  Prediction of Residual Stress and Part Distortion in Selective Laser Melting , 2016 .

[29]  F. Veniali,et al.  Roughness modeling of AlSi10Mg parts fabricated by selective laser melting , 2017 .

[30]  Peter C. Collins,et al.  Microstructural Control of Additively Manufactured Metallic Materials , 2016 .

[31]  Chandrika Kamath,et al.  Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing , 2014 .

[32]  Amrita Basak,et al.  Epitaxy and Microstructure Evolution in Metal Additive Manufacturing , 2016 .

[33]  E. Garboczi,et al.  Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control , 2014, Journal of research of the National Institute of Standards and Technology.

[34]  Robert F. Singer,et al.  Grain structure evolution in Inconel 718 during selective electron beam melting , 2016 .

[35]  J.-L. Desbiolles,et al.  Modeling of equiaxed microstructure formation in casting , 1989 .

[36]  Sarma B Gorti,et al.  Phase Field Simulations of Autocatalytic Formation of Alpha Lamellar Colonies in Ti-6Al-4V , 2016, Metallurgical and Materials Transactions A.

[37]  D. P. Koistinen,et al.  A general equation prescribing the extent of the austenite-martensite transformation in pure iron-carbon alloys and plain carbon steels , 1959 .

[38]  Xibing Gong,et al.  Phase-Field Modeling of Microstructure Evolution in Electron Beam Additive Manufacturing , 2015 .

[39]  R. Everson,et al.  Surface roughness analysis, modelling and prediction in selective laser melting , 2013 .

[40]  Karen M. Taminger,et al.  A coupled finite element cellular automaton model to predict thermal history and grain morphology of Ti-6Al-4V during direct metal deposition (DMD) , 2016 .

[41]  Yuebin Guo,et al.  A multiscale modeling approach for fast prediction of part distortion in selective laser melting , 2016 .

[42]  A. Karma,et al.  Phase-Field Simulation of Solidification , 2002 .

[43]  Vasily Ploshikhin,et al.  Evolution of grain structure during laser additive manufacturing. Simulation by a cellular automata method , 2016 .

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

[45]  Y. Shin,et al.  Multi-scale modeling of solidification and microstructure development in laser keyhole welding process for austenitic stainless steel , 2015 .

[46]  W. A. Johnson.  Reaction Kinetics in Processes of Nucleation and Growth , 1939 .

[47]  Jack Beuth,et al.  Prediction of lack-of-fusion porosity for powder bed fusion , 2017 .

[48]  C. Körner,et al.  Mesoscopic simulation of selective beam melting processes , 2011 .

[49]  L. Papadakis,et al.  Numerical Computation of Component Shape Distortion Manufactured by Selective Laser Melting , 2014 .

[50]  Matthias Markl,et al.  Multiscale Modeling of Powder Bed–Based Additive Manufacturing , 2016 .

[51]  M. Zhu,et al.  A Modified Cellular Automaton Model for the Simulation of Dendritic Growth in Solidification of Alloys , 2001 .

[52]  Y. Shin,et al.  Multiscale Modeling of Transport Phenomena and Dendritic Growth in Laser Cladding Processes , 2011 .

[53]  Carolin Körner,et al.  Evaporation model for beam based additive manufacturing using free surface lattice Boltzmann methods , 2014 .

[54]  R. B. Wicker,et al.  Advanced metal powder based manufacturing of complex components by electron beam melting , 2009 .

[55]  A. Ilin,et al.  Advanced numerical method for fast prediction of welding distortions of large aircraft structures , 2010 .

[56]  Kai Zeng,et al.  A review of defect modeling in laser material processing , 2017 .

[57]  Carolin Körner,et al.  Defect generation and propagation mechanism during additive manufacturing by selective beam melting , 2014 .

[58]  P. Masson,et al.  Estimation of the parameters of a Gaussian heat source by the Levenberg–Marquardt method: Application to the electron beam welding , 2007 .

[59]  C. C. Murgau.  Microstructure model for Ti-6Al-4V used in simulation of additive manufacturing , 2016 .

[60]  Amirhesam Amerinatanzi,et al.  Fabrication of NiTi through additive manufacturing: A review , 2016 .

[61]  C. Knight.  Theoretical Modeling of Rapid Surface Vaporization with Back Pressure , 1979 .

[62]  D. Mynors,et al.  A three-dimensional finite element analysis of the temperature field during laser melting of metal powders in additive layer manufacturing , 2009 .

[63]  C. Kamath,et al.  Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges , 2015 .

[64]  S. Felicelli,et al.  Dendrite growth simulation during solidification in the LENS process , 2010 .

[65]  Y. Shin,et al.  A novel integrated model combining Cellular Automata and Phase Field methods for microstructure evolution during solidification of multi-component and multi-phase alloys , 2011 .

[66]  Moataz M. Attallah,et al.  On the role of thermal fluid dynamics into the evolution of porosity during selective laser melting , 2015 .

[67]  Brent Stucker,et al.  An Integrated Approach to Additive Manufacturing Simulations Using Physics Based, Coupled Multiscale Process Modeling , 2014 .

[68]  Y. Shin,et al.  Analysis of multi-phase interaction and its effects on keyhole dynamics with a multi-physics numerical model , 2014 .

[69]  Alexander M. Rubenchik,et al.  Denudation of metal powder layers in laser powder bed fusion processes , 2016 .

[70]  O. Ojo,et al.  Numerical modeling of microstructure evolution during laser additive manufacturing of a nickel-based superalloy , 2014 .

[71]  Radovan Kovacevic,et al.  Numerical Modeling of Heat Distribution in the Electron Beam Melting® of Ti-6Al-4V , 2013 .

[72]  Gustav Amberg,et al.  Phase-field simulations of non-isothermal binary alloy solidification , 2001 .

[73]  Chandrika Kamath,et al.  Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W , 2014 .

[74]  Long-Qing Chen.  Phase-Field Models for Microstructure Evolution , 2002 .

[75]  A. Beese,et al.  Residual stress mapping in Inconel 625 fabricated through additive manufacturing: Method for neutron diffraction measurements to validate thermomechanical model predictions , 2017 .

[76]  Ninggang Shen,et al.  THERMAL MODELING OF ELECTRON BEAM ADDITIVE MANUFACTURING PROCESS - POWDER SINTERING EFFECTS , 2012 .

[77]  J. K. Chen,et al.  Numerical simulation of laser irradiation to a randomly packed bimodal powder bed , 2009 .

[78]  Heike Emmerich,et al.  Phase-field modeling of microstructure formation during rapid solidification in Inconel 718 superalloy , 2015 .

[79]  T. DebRoy,et al.  Calculation of weld metal composition change in high-power conduction mode carbon dioxide laser-welded stainless steels , 1993 .

[80]  Y. Shin,et al.  Numerical Modeling of Transport Phenomena and Dendritic Growth in Laser Spot Conduction Welding of 304 Stainless Steel , 2012 .

[81]  K. Salonitis,et al.  Simulation of metallic powder bed additive manufacturing processes with the finite element method: A critical review , 2017 .

[82]  Pan Michaleris,et al.  Thermomechanical Modeling of Additive Manufacturing Large Parts , 2014 .

[83]  C. Panwisawas,et al.  A Multi‐Scale Multi‐Physics Approach to Modelling of Additive Manufacturing in Nickel‐Based Superalloys , 2016 .

[84]  Pengsheng Wei.  Thermal Science of Weld Bead Defects: A Review , 2011 .

[85]  J. Sienz,et al.  A review of Computational Modelling of Additive Layer Manufacturing - multi-scale and multi-physics , 2014 .

[86]  Ulrich Rüde,et al.  Electron Beam Absorption Algorithms for Electron Beam Melting Processes Simulated by a Three-Dimensional Thermal Free Surface Lattice Boltzmann Method in a Distributed and Parallel Environment , 2013, ICCS.

[87]  Vinod Yadava,et al.  Finite element analysis of temperature distribution in single metallic powder layer during metal laser sintering , 2007 .

[88]  Robert F. Singer,et al.  Tailoring the grain structure of IN718 during selective electron beam melting , 2014 .

[89]  C. Fu,et al.  A predictive model and validation of laser cutting of nitinol with a novel moving volumetric pulsed heat flux , 2014 .

[90]  Jack Beuth,et al.  Synchrotron-Based X-ray Microtomography Characterization of the Effect of Processing Variables on Porosity Formation in Laser Power-Bed Additive Manufacturing of Ti-6Al-4V , 2017 .

[91]  Boris Wilthan,et al.  Thermophysical Properties of Solid and Liquid Ti-6Al-4V (TA6V) Alloy , 2006 .

[92]  Michael F. Zäh,et al.  Modelling and simulation of electron beam melting , 2010, Prod. Eng..

[93]  Yuebin Guo,et al.  Three-Dimensional Temperature Gradient Mechanism in Selective Laser Melting of Ti-6Al-4V , 2014 .

[94]  Shawn P. Moylan,et al.  Measurement Science Needs for Real-time Control of Additive Manufacturing Powder Bed Fusion Processes , 2015 .

[95]  J. Goldak,et al.  Computational Welding Mechanics , 2005 .

[96]  M. Avrami.  Kinetics of Phase Change. I General Theory , 1939 .

[97]  Yang Liu,et al.  Theoretical and experimental study on surface roughness of 316L stainless steel metal parts obtained through selective laser melting , 2016 .

[98]  C. Kamath,et al.  Overview of modelling and simulation of metal powder bed fusion process at Lawrence Livermore National Laboratory , 2015 .

[99]  Orion L. Kafka,et al.  Linking process, structure, property, and performance for metal-based additive manufacturing: computational approaches with experimental support , 2016 .

[100]  David Turnbull,et al.  Rate of Nucleation in Condensed Systems , 1949 .

[101]  C. Gandin,et al.  Probabilistic modelling of microstructure formation in solidification processes , 1993 .

[102]  Ryan R. Dehoff,et al.  Computational modeling of residual stress formation during the electron beam melting process for Inconel 718 , 2015 .