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Predict macro to microscale properties of AM parts by manufacturing process simulation

Wednesday (08.11.2017)
15:20 - 15:40
Part of:

Additive manufacturing (AM), especially when done by metal powder bed fusion processes, offers new possibilities to produce optimized lightweight designs, that were not producible before by conventional manufacturing technologies. This is already true for typical steel or nickel-based alloys, but using lightweight materials like titanium and aluminium can even increase the weight-saving potential.

AM is a primary forming manufacturing process with similarities to welding and casting. As a consequence the AM build process influences the part properties not only at a macroscopic level, e.g. in terms of distortion against the target geometry, but also down to a micro scale level, e.g. in terms of metallic microstructure.

A scalable additive manufacturing process simulation approach is presented that aims at predicting as well macro as micro scale properties induced by the build process. On a macro scale a fast analysis approach quickly delivers the main properties like distortion and the related stress state. On a micro scale a welding simulation of the laser beam melting process enables the prediction of the thermal history and the related evolution of the microstructure and the final material properties. In between both extremes meso scale approaches can deliver a medium level of result details at reasonable analysis costs.

Additionally it is important not only to look at the build process, but also at the following post-processing chain. Also here properties like distortion, stress and microstructure can change. Finally the possibility to virtually optimize the AM process chain before going into the real process is discussed and an outlok to further planned developments given.

Dr.-Ing. Patrick Mehmert
simufact engineering gmbh
Additional Authors:
  • Dr. Ayman Salem
    Materials Resources LLC
  • Dr. Hendrik Schafstall
    simufact engineering GmbH