Presents the additive manufacturing process-structure-property relationships and optimizes the manufacturing parameters and machines via computational modeling techniques
Computational Modeling of Additive Manufacturing provides a step-by-step guide, covering topics from basic physics and governing equations to the implementation, experimental validation, model capability, and physical mechanisms obtained from simulation, as well as expert perspectives on future outlooks. With a well-rounded exploration of key areas, this book integrates various modeling techniques, including multi-physics modeling of powder, fluid and solid mechanics, heat transfer, microstructure evolutions, data-driven analysis, and a synergy of modeling with other techniques. Modeling of various additive manufacturing processes are included, such as laser/electron beam powder bed fusion, directed energy deposition, binder jetting, and material extrusion.
The book presents comprehensive simulations covering a variety of issues for the process-structure-property relationships, including:
- Multi-phase flow modeling of powder dynamics in powder-bed-based additive manufacturing processes
- Multi-physics modeling of molten pool dynamics in fusion-based additive manufacturing processes, with mechanistic heat source model, composition-dependent evaporation and chemical reaction models
- Modeling of microstructure evolutions including grain and dendrite evolutions
- Multi-scale modeling of thermal and residual stresses, and the room- and high-temperature mechanical properties of the additively manufactured parts
- Data-driven surrogate modeling, uncertainty quantification and optimization, and the synergy with digital twins, smart diagnostics, and control
This book is an essential first-of-its-kind reference for researchers in this specific area, and the larger area of additive manufacturing focusing on experiments, materials design, mechanics, and other areas of interest.
Table of Contents:
Preface xi
Acknowledgments xv
Acronyms xvii
1 Introduction 1
2 Modeling of powder dynamics 5
2.1 Introduction 5
2.2 Methodology 6
2.3 Experimental validation 14
2.4 Modeling of powder spreading in powder-bed-based additive manufacturing 16
2.5 Modeling of powder feeding in powder-feed directed energy deposition 28
2.6 Modeling of spattering in laser powder bed fusion 33
2.7 Summary 39
3 Modeling of melt pool dynamics 43
3.1 Introduction 43
3.2 Methodology 46
3.3 Simulation of single-material PBF process 92
3.4 Simulation of multi-material PBF process 124
3.5 Simulation of AM process under external fields 159
3.6 Summary 180
4 Modeling of micro-structure evolutions 181
4.1 Introduction 181
4.2 Modeling of grain evolutions 182
4.3 Modeling of dendrite evolutions 199
4.4 Modeling of precipitation 231
4.5 Summary 247
5 Modeling of thermal/residual stresses 249
5.1 Introduction 249
5.2 Experimental validation 253
5.3 Micro-scale model of thermal/residual stresses 255
5.4 Meso-scale model of thermal/residual stresses 278
5.5 Macro-scale model of thermal/residual stresses 292
5.6 Model of dislocation evolution driven by thermal stresses 302
5.7 Model of dynamic recrystallization driven by thermal stresses 317
5.8 Summary 324
6 Modeling of mechanical properties of AM materials 327
6.1 Introduction 327
6.2 Methodology 329
6.3 Modeling of mechanical properties of AM AlSi10Mg: room- and high-temperature 331
6.4 Brief summary 343
6.5 Strain localization in additively manufactured material 344
6.6 Fracture and fatigue modeling in AM materials 364
6.7 Summary 377
7 Data-driven Modelling and Analysis 379
7.1 Introduction 379
7.2 Data Foundations and Modelling Workflow for AM 380
7.3 Statistical Methods for Data-driven Analysis 381
7.4 Data-driven Surrogate Modelling 388
7.5 Uncertainty Quantification 421
7.6 Summary 431
8 Synergy of Modelling with Other Techniques 433
8.1 Introduction 433
8.2 Data Collection 435
8.3 Data Handling and Preprocessing 439
8.4 Digital Twin for AM 451
8.5 Towards Closed-Loop Control 455
8.6 Summary 460
About the Author :
WENTAO YAN, PhD, is a Tenured Associate Professor in the Department of Mechanical Engineering at the National University of Singapore (NUS). Since 2014, he has been working on multi-scale multi-physics modeling, experimental investigation and data analysis of additive manufacturing. He has published >140 papers on flagship journals and his team was the winner in the 2022 NIST AM Bench Simulation Challenges, winning 9 awards in 25 tests.
YANMING ZHANG, PhD, is a Research Fellow in the Department of Mechanical Engineering at NUS. His research focuses on the multiphase flow modeling of multi-material additive manufacturing.
DAIJUN HU, PhD, is a Research Fellow in the Department of Mechanical Engineering at NUS. His research focuses on residual stress, dislocation dynamics and fracture, providing mechanistic insights into material behavior through computational modeling of additive manufacturing.
YUHAN JU is a PhD candidate in the Department of Mechanical Engineering at NUS. Her research focuses on the modeling of microstructure evolutions in additive manufacturing at grain and dendrite scales with the phase-field and cellular automaton methods.
YIMING LIU is a PhD student under the Integrative Sciences and Engineering Programme at NUS. His research focuses on data-driven modeling, diagnostics and close-loop control in additive manufacturing.
