Multi-scale Modelling Approach for Contributing to Reduced Distortion in Parts Made by Laser-based Powder Bed Fusion

Within this paper, a control volume-based multi-scale approach for heat input modelling in laser-based powder bed fusion of metals is described. Thereby, the Rosenthal equation is used to analyse beam-powder interaction for a single laser track. Based on both the Rosenthal results for melt pool dimensions and experimentally determined melt pool depth, a single layer model is developed. Results for the temperature field, gathered by applying the single layer model, serve as data for validating the control volume-based approach on the build-up scale. Finally, a case study with a turbine blade delivers the proof-of-concept for the applied modelling approaches, because process-related distortions are reduced by more than 40% through pre-deforming the blade according to build-up simulation results.