| Abstract Scope |
This talk presents several lessons learned from calibration and validation of thermal process modeling for laser powder bed fusion, which include both finite-element based scan-resolved and layerwise process simulation model. Using interlayer temperature obtained by in-situ infrared camera to calibrate/validate layerwise model, sensitivity analysis of the different physics in the boundary conditions will be presented. These physics include the time duration of applying heat, convective heat loss, radiative heat loss, inclusion/exclusion of surrounding powders. Additionally, it will be shown that surface temperature in a part that accumulates heat easily can be controlled by optimizing dwell time to ensure microstructure consistency. For scan-resolved process modeling, there exist deficiencies for conventional heat source model in handling the effects of local geometry (e.g. overhang) and local thermal conditions on melt pool geometry and cooling rates. New heat source models overcoming these deficiencies will be presented with a focus on their accuracy and efficiency. |