| About this Abstract |
| Meeting |
2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
|
| Symposium
|
2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
|
| Presentation Title |
Evaluating Residual Heat-driven Melt Pool Variation through GPU-based Thermal Process Simulation |
| Author(s) |
David Scott Anderson, Haolin Zhang, Shawn Hinnebusch, Xiayun Zhao, Albert To, Florian Dugast, Alaa Olleak |
| On-Site Speaker (Planned) |
David Scott Anderson |
| Abstract Scope |
Despite well-studied process parameters, melt pool variation due to residual heat accumulation has remained a potential source of porosity and spattering defects. However, at the part-scale, traditional finite element methods require extremely fine meshes relative to the part scale to accurately resolve melt pool dimensions, resulting in long processing times and high memory requirements. To resolve this, a matrix-free finite element model has been developed, implementing adaptive remeshing and GPU-based parallelization to improve processing times. The model has been calibrated against optical microscopy data to improve the implementation of a Goldak heat source model, and compared against in-situ monitoring data to validate simulated results. This model enables investigation into melt pool variations at the part scale due to residual heating effects from previous layers, part geometry, and hatching patterns, to better understand and predict transitions from conduction to keyhole regimes. |
| Proceedings Inclusion? |
Definite: Post-meeting proceedings |