Title: Hierarchical Simulation of Laser Powder Bed Fusion (L-PBF) on Part Scale


Name: Luca Luberto


Phone: +49 (0) 631/205-4638


Project description:


Starting situation

Laser powder bed fusion is an additive manufacturing process in which a laser melts powdered material layer by layer and forms a component by resolidification. The local application of the laser leads to high heating and cooling rates which, in the case of unfavorable parameter settings, can result in anisotropic material properties and crack-promoting residual stresses. To avoid this, the process parameters such as laser power, scanning speed and layer height must be determined optimally and individually for a component. In order to accurately describe the temperature field of the process, phase transitions and physical effects such as Marangoni convection must be taken into account. This leads to very computationally expensive flow simulations, which can only be used for small components.




In this project, a holistic model for the process simulation of large components is to be developed, in which temperature-induced deformations and (inherent) stresses can be predicted. The temperature field is represented by effective material values, which reflect the process-specific effects and come from own flow simulations. By using a proprietary, GPU-based code framework, even large components with many degrees of freedom can be simulated efficiently.


Expected Results

The project enables a holistic view of the process for large components, where the parameter-component interaction can be studied efficiently.