Thermo-mechanical simulations of powder bed fusion processes: accuracy and efficiency

Effects of powder recycling on stainless steel powder and built material properties in metal powder bed fusion processes

Meshfree simulations of thermo-mechanical ductile fracture

In this work, a meshfree method is used to simulate thermo-mechanical ductile fracture under finite deformation. A Galerkin meshfree formulation incorporating the Johnson-Cook damage model is implemented in numerical computations. We are interested in the simulation of thermomechanical effects on ductile fracture under large scale yielding. A rate form adiabatic split is proposed in the constit...

Laser powder bed fusion of Ti-6Al-4V parts: Thermal modeling and mechanical implications

A continuum-scale modeling approach is developed and employed with three-dimensional finite element analysis (FEA), for simulating the temperature response of a Ti-6Al-4V, two-layered parallelepiped with dimensions of 10×5×0.06 mm during Laser Powder Bed Fusion (L-PBF), a metals additive manufacturing (AM) method. The model has been validated using experimental melt pool measurements from the l...

Efficient thermo-mechanical model for solidification processes

A new, computationally efficient algorithm has been implemented to solve for thermal stresses, strains, and displacements in realistic solidification processes which involve highly nonlinear constitutive relations. A general form of the transient heat equation including latent-heat from phase transformations such as solidification and other temperature-dependent properties is solved numerically...

Some aspects on designing for metal Powder Bed Fusion

Additive Manufacturing (AM) using the Powder Bed Fusion (PBF) is a relatively new manufacturing method that is capable of creating shapes that was previously practically impossible to manufacture. Many think it will revolutionize how manufacturing will be done in the future. This thesis is about some aspects of when and how to Design for Additive Manufacturing (DfAM) when using the PBF method i...