81 - Novel Multi-Scale Additive Manufacturing PBF Process Simulation Approach for Location-Specific Defect Predictions within Full-Scale Geometries

Abstract

Additive Manufacturing process simulation for metal laser powder bed fusion has achieved a degree of mainstream status in recent years. Modeling, however, still has challenges that are being actively worked and overcome. One major limitation is the inability to deliver linked, multi-scale results over a full part volume, in a reasonable calculation time. It is known that running a complete part at the individual scan vector level could take computational times well in excess of that allowed for industrial design and analysis efforts. The present work describes a novel multi-scale, analytical model-based process simulation approach that was developed by Pratt & Whitney (P&W), and the Raytheon Technologies Research Center (RTRC), and is being incorporated into a commercial software framework by Hexagon Manufacturing Intelligence, Inc. (Hexagon). The model enables thermal history and defect prediction at the individual scan vector and powder layer level in minutes. The model is able to predict risk of local defects including keyholing, lack of fusion, balling up, and surface roughness. Further it can determine the process parameter window locally for any location within the part, based on the local geometry and temperature of the substrate before the laser is applied locally, which is calculated by a combined analytical/FE approach on the part scale and also depends on material properties, operational conditions, and part geometry. The analysis also includes probabilistic effects and supports uncertainty quantification. This solution enables engineers to evaluate build processes and risk of defects given the proposed process parameters, or even to define how process parameters and scan vectors need to be modified locally to mitigate risk. It also enables the identification of high-risk areas where inspection and testing focus would be the most valuable to support model-guided qualification and certification plans.

Speaker

Simon Poly

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Conference

81 - Novel Multi-Scale Additive Manufacturing PBF Process Simulation Approach for Location-Specific Defect Predictions within Full-Scale Geometries

Date/Time

20/03/2024

5:20 pm -5:40 pm

Location

Room 8