A thermo-mechanical phase-field fracture model: Application to hot cracking simulations in additive manufacturing

Thermal fracture is prevalent in many engineering problems and one of the most devastating defects metal additive manufacturing. Due to interactive underlying physics involved, computational simulation such a process challenging. In this work, we propose thermo-mechanical phase-field model, which based on thermodynamically consistent derivation. The influence different coupling terms as damage-informed thermomechanics heat conduction temperature-dependent properties, well formulations, are discussed. model numerically implemented with finite element method. Finally, applied simulate hot cracking Thereby not only thermal strain but also solidification shrinkage considered. As for profile, both analytical temperature solution numerical field around melting pool taken into account. Based latter approach, parameters further studied. study reveals that takes dominant role formation circumferential crack, while gradient mostly responsible central crack. Process parameter demonstrates higher laser power slower scanning speed favorable keyhole mode lower quicker tend form cracking. predictions patterns good agreement similar experimental observations, showing capability studies.