This presentation provides an overall modeling framework encompassing fast-acting physics-based method to predict melt pool geometry and formation of defects in additively manufactured components produced by laser powder bed fusion process. The instability and subsequent balling, unstable key holing and lack of fusion have been modeled using primarily energy conservation and the effect of temperature dependent surface tension coefficient. The analytical model predicts temperature field to resolve melt pool details and then was extended beyond single track to predict formation of defects in multilayer deposits. The defect types and position have been defined and evaluated and used to construct process maps for different metals and alloys. Marangoni convection has been used to resolve defects related to Raleigh-Ritz instability and subsequent balling that can cause porosity in subsequent layers due to layer thickness variation. Part level experiments were performed to validate the model capability to predict defect location in additively manufactured part.
- Understand the significance of analytical modeling approaches to create process maps for additive manufacturing.
- Describe the important defects typically present in components made in powder bed fusion additive manufacturing processes.