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Additive Manufacturing (AM) is a transformative manufacturing technology enabling direct fabrication of complex parts layer-be-layer from 3D modeling data. Among AM applications, the fabrication of Functionally Graded Materials (FGMs) has…
The production of lightweight metal lattice structures has received much attention due to the recent developments in additive manufacturing (AM). The design flexibility comes, however, with the complexity of the underlying physics. In fact,…
In our recent work [H. Zhang, F.X. Trias, A. Oliva, D. Yang, Y. Tan, Y. Sheng. PIBM: Particulate immersed boundary method for fluid-particle interaction problems. Powder Technology. 272(2015), 1-13.], a particulate immersed boundary method…
The mitigation of material defects from additive manufacturing (AM) processes is critical to reliability in their fabricated parts and is enabled by modeling the complex relations between available build monitoring signals and final…
Accurately predicting the temperature field in metal additive manufacturing (AM) processes is critical to preventing overheating, adjusting process parameters, and ensuring process stability. While physics-based computational models offer…
Selective Laser Melting (SLM) is an additive manufacturing technology that builds three dimensional parts by melting layers of metal powder together with a laser that traces out a desired geometry. SLM is popular in industry, however the…
In metal Additive Manufacturing (AM), monitoring the temperature of the Melt Pool (MP) is crucial for ensuring part quality, process stability, defect prevention, and overall process optimization. Traditional methods, are slow to converge…
Laser powder bed fusion (LPBF) holds promise to efficiently produce metal parts. However, LPBF incurs stochastic melt pool (MP) spattering, which would roughen workpiece in-process surface, thus weakening inter-layer bonding and causing…
Additive manufacturing by laser powder bed fusion (LPBF) offers material versatility, capability for complex geometries, and control of mechanical properties and microstructure. However, achieving high-quality output requires process…
An increasing number of laser powder bed fusion machines use off-axis infrared cameras to improve online monitoring and data-driven control capabilities. However, there is still a severe lack of algorithmic solutions to properly process the…
In context of laser powder bed fusion (L-PBF), it is known that the properties of the final fabricated product highly depend on the temperature distribution and its gradient over the manufacturing plate. In this paper, we propose a novel…
We present RAISE-LPBF, a large dataset on the effect of laser power and laser dot speed in powder bed fusion (LPBF) of 316L stainless steel bulk material, monitored by on-axis 20k FPS video. Both process parameters are independently sampled…
While multiple sensors are used for real-time monitoring in additive manufacturing, not all provide practical or reliable process insights. For example, high-speed X-ray imaging offers valuable spatial information about subsurface melt pool…
Additive manufacturing (AM) of metallic components promises many advantages over conventional manufacturing processes through high design flexibility across multiple length scales and precision coupled with an astonishing combination of…
In a powder bed fusion additive manufacturing (AM) process, the balling effect has a significant impact on the surface quality of the printing parts. Surface wetting helps the bonding between powder and substrate and the inter-particle…
In Laser Powder Bed Fusion (LPBF), the applied laser energy produces high thermal gradients that lead to unacceptable final part distortion. Accurate distortion prediction is essential for optimizing the 3D printing process and…
Powder-based additive manufacturing has transformed the manufacturing industry over the last decade. In Laser Powder Bed Fusion, a specific part is built in an iterative manner in which two-dimensional cross-sections are formed on top of…
Additive manufacturing (AM) allows for manufacturing of complex three-dimensional geometries not typically realizable with standard subtractive manufacturing practices. The internal microstructure of a 3D printed component can have a…
In this paper we outline the development of a scalable PBF thermal history simulation built on CAPL and based on melt pool physics and dynamics. The new approach inherits linear scalability from CAPL and has three novel ingredients.…
We present a novel computational paradigm for process design in manufacturing processes that incorporates simulation responses to optimize manufacturing process parameters in high-dimensional temporal and spatial design spaces. We developed…