Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

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, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes

Phase-field approach to polycrystalline solidification including heterogeneous and homogeneous nucleation

Advanced phase-field techniques have been applied to address various aspects of polycrystalline solidification including different modes of crystal nucleation. The height of the nucleation barrier has been determined by solving the appropriate Euler-Lagrange equations. The examples shown include the comparison of various models of homogeneous crystal nucleation with atomistic simulations for the single component hard-sphere fluid. Extending previous work for pure systems (Gránásy L, Pusztai T, Saylor D and Warren J A 2007 Phys. Rev. Lett. 98 art no 035703), heterogeneous nucleation in unary and binary systems is described via introducing boundary conditions that realize the desired contact angle. A quaternion representation of crystallographic orientation of the individual particles (outlined in Pusztai T, Bortel G and Gránásy L 2005 Europhys. Lett. 71 131) has been applied for modeling a broad variety of polycrystalline structures including crystal sheaves, spherulites and those built of crystals with dendritic, cubic, rhombododecahedral, truncated octahedral growth morphologies. Finally, we present illustrative results for dendritic polycrystalline solidification obtained using an atomistic phase-field model

Controlling the energy of defects and interfaces in the amplitude expansion of the phase-field crystal model

One of the major difficulties in employing phase field crystal (PFC) modeling and the associated amplitude (APFC) formulation is the ability to tune model parameters to match experimental quantities. In this work we address the problem of tuning the defect core and interface energies in the APFC formulation. We show that the addition of a single term to the free energy functional can be used to increase the solid-liquid interface and defect energies in a well-controlled fashion, without any major change to other features. The influence of the newly added term is explored in two-dimensional triangular and honeycomb structures as well as bcc and fcc lattices in three dimensions. In addition, a finite element method (FEM) is developed for the model that incorporates a mesh refinement scheme. The combination of the FEM and mesh refinement to simulate amplitude expansion with a new energy term provides a method of controlling microscopic features such as defect and interface energies while simultaneously delivering a coarse-grained examination of the system.Comment: 14 pages, 9 figure

Dynamic development of hydrofracture

Many natural examples of complex joint and vein networks in layered sedimentary rocks are hydrofractures that form by a combination of pore fluid overpressure and tectonic stresses. In this paper, a two-dimensional hybrid hydro-mechanical formulation is proposed to model the dynamic development of natural hydrofractures. The numerical scheme combines a discrete element model (DEM) framework that represents a porous solid medium with a supplementary Darcy based pore-pressure diffusion as continuum description for the fluid. This combination yields a porosity controlled coupling between an evolving fracture network and the associated hydraulic field. The model is tested on some basic cases of hydro-driven fracturing commonly found in nature, e.g., fracturing due to local fluid overpressure in rocks subjected to hydrostatic and nonhydrostatic tectonic loadings. In our models we find that seepage forces created by hydraulic pressure gradients together with poroelastic feedback upon discrete fracturing play a significant role in subsurface rock deformation. These forces manipulate the growth and geometry of hydrofractures in addition to tectonic stresses and the mechanical properties of the porous rocks. Our results show characteristic failure patterns that reflect different tectonic and lithological conditions and are qualitatively consistent with existing analogue and numerical studies as well as field observations. The applied scheme is numerically efficient, can be applied at various scales and is computational cost effective with the least involvement of sophisticated mathematical computation of hydrodynamic flow between the solid grains

PyFrac: A planar 3D hydraulic fracture simulator

Fluid driven fractures propagate in the upper earth crust either naturally or in response to engineered fluid injections. The quantitative prediction of their evolution is critical in order to better understand their dynamics as well as to optimize their creation. We present a Python implementation of an open-source hydraulic fracture propagation simulator based on the implicit level set algorithm originally developed by Peirce & Detournay (2008) -- "An implicit level set method for modeling hydraulically driven fractures". Comp. Meth. Appl. Mech. Engng, (33-40):2858--2885. This algorithm couples a finite discretization of the fracture with the use of the near tip asymptotic solutions of a steadily propagating semi-infinite hydraulic fracture. This allows to resolve the multi-scale processes governing hydraulic fracture growth accurately, even with relatively coarse meshes. We present an overview of the mathematical formulation, the numerical scheme and the details of our implementation. A series of problems including a radial hydraulic fracture verification benchmark, the propagation of a height contained hydraulic fracture, the lateral spreading of a magmatic dyke and the handling of fracture closure are presented to demonstrate the capabilities, accuracy and robustness of the implemented algorithm