Powder Bed Models - Numerical Assessment of As-Built Quality

H.-W. Mindt, Brian Shula, M. Megahed, A. D. Peralta, J. Neumann, Powder Bed Models – Numerical Assessment of As-Built Quality, AIAA 2016-1657, AIAA Science and Technology Forum and Exposition 2016, 4-8 January, 2016, San Diego, CA, USA. DOI: 10.2514/6.2016-1657.

This paper presents new models for Direct Metal Laser Melting proceses (DMLM) with particular focus on how process paramters lead to different porosity levels. The numerical results are compared with micrographs validating numerical predictions. The results of process models are also used to model the thermal loads acting on the work piece during the build process. The final distortions and their dependencies on deposition strategies are compared with experimental measurements confirming the overall simulation chain.