Scan-by-scan part-scale thermal modelling for defect prediction in metal additive manufacturing

A part-scale thermal modeling concept is implemented to predict defect distributions in additively manufactured components. Utilizing the principle of superposition, complete history builds can be simulated within time frame required for real physical builds, without spatial or temporal coarsening. Demonstrating on a component with typical laser powder bed fusion parameters, simulations show that addition power schedule, defects depend geometry, scanning strategy, and heat accumulation. The features governing formation at are analyzed, simple rule predicting presented.