Simulation of the laser powder bed fusion process with a holistic workflow

The laser powder bed fusion process is holistically modelled by means of suitable numerical methods. The Discrete Element Method is used for powder spreading simulations yielding realistic powder beds. Smoothed Particle Hydrodynamics simulations are then used to study the thermal-viscous flow in the melt pool considering laser energy absorption, radiation, heat transfer, melting and re-solidification, surface tension, Marangoni currents and vaporization pressure. The melt pool simulation is coupled to a Cellular Automaton, which calculates the growth of dendritic grains based on the temperature field and, thus, provides a prediction for the microstructure formed during solidification. The obtained microstructure serves as input for Crystal Plasticity Finite Element Analyses to qualitatively describe texture dependent mechanical properties.