Computationally efficient model to predict the evolution in the thermal field in the EB-PBF and LP-DED processes

Understanding the development of a number of defects found in components fabricated by the metal Additive Manufacturing (AM) processes requires an understanding of the evolution in the thermal field within the component at both the macro- and meso-scales. As a first step, in this work, the agglomeration method was used in combination with a time-averaged input of energy to simulate the macro-scale evolution in temperature. Two example processes: 1) laser-based powder-fed directed energy deposition; and 2) electron beam powder bed fusion, are used to demonstrate the modelling methodology. The approach employed focuses on ensuring the conservation of heat and is applied using ABAQUS. The two applications have been validated by comparing the predicted thermal behaviour with process-derived data. The results indicate that this method is an efficient strategy to predict the thermal field at the scale of the component being fabricated.