PBF-LB/M multiphysics process simulation from powder to mechanical properties

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