Related papers: A Framework for Simulating the Path-level Residual…
Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this…
Metal additive manufacturing (AM) processes, such as laser powder bed fusion (L-PBF), can yield high-value parts with unique geometries and features, substantially reducing costs and enhancing performance. However, the material properties…
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…
Powder bed additive manufacturing processes such as laser powder bed fusion (LPBF) or binder jetting (BJ) benefit from using fine (D50 $\leq20~\mu m$) powders. However, the increasing level of cohesion with decreasing particle size makes…
Ensuring the quality and reliability of Metal Additive Manufacturing (MAM) components is crucial, especially in the Laser Powder Bed Fusion (L-PBF) process, where melt pool defects such as keyhole, balling, and lack of fusion can…
We present a data-driven, differentiable neural network model designed to learn the temperature field, its gradient, and the cooling rate, while implicitly representing the melt pool boundary as a level set in laser powder bed fusion. The…
A thermodynamic framework has been developed for a class of amorphous polymers used in fused deposition modeling (FDM), in order to predict the residual stresses and the accompanying distortion of the geometry of the printed part (warping).…
The present work introduces a novel numerical approach for the process modeling of fiber-reinforced thermoset polymers at the micro-scale level, that can be used to predict curing-induced residual stresses. The cure kinetics is described…
Laser-based metal processing including welding and three dimensional printing, involves localized melting of solid or granular raw material, surface tension-driven melt flow and significant evaporation of melt due to the applied very high…
Integrating topology optimization and additive manufacturing (AM) technology can facilitate innovative product development. However, laser powder bed fusion, which is the predominant method in metal AM, can lead to issues such as residual…
The thermal and mechanical behaviors of powders are important for various additive manufacturing technologies. For powder bed fusion, capturing the temperature profile and the packing structure of the powders prior to melting is challenging…
The stochastic formation of defects during Laser Powder Bed Fusion (L-PBF) negatively impacts its adoption for high-precision use cases. Optical monitoring techniques can be used to identify defects based on layer-wise imaging, but these…
Laser material processing has emerged as a versatile and indispensable tool in various industries, including manufacturing, healthcare, and materials science. However, the interaction of a lasers with surfaces is highly dependent on a large…
We present a multi-level delumping method suitable for thermal enhanced oil recovery processes, for which hydrocarbon components are vaporized under high temperatures, move downstream in the gas phase and condense back to the liquid phase.…
The bottleneck of alloy design for powder-based additive manufacturing (AM) resides in customized powder production - an expensive and time-consuming process hindering the rapid closed-loop design iterations. This study analyzed an…
Insufficient overlap between the melt pools produced during Laser Powder Bed Fusion (L-PBF) can lead to lack-of-fusion defects and deteriorated mechanical and fatigue performance. In-situ monitoring of the melt pool subsurface morphology…
In this study, the effects of surface roughness and pore characteristics on fatigue lives of laser powder bed fusion (LPBF) Ti-6Al-4V parts were investigated. The 197 fatigue bars were printed using the same laser power but with varied…
Thermal fracture is prevalent in many engineering problems and is one of the most devastating defects in metal additive manufacturing. Due to the interactive underlying physics involved, the computational simulation of such a process is…
Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However,…
Femtosecond laser surface processing (FLSP) is an emerging fabrication technique to efficiently control the surface morphology of many types of materials including metals. However, the theoretical understanding of the FLSP formation…