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As a promising powder-based additive manufacturing technology, selective laser melting (SLM) has gained great popularity in recent years. However, experimental observation of the melting and solidification process is very challenging. This hinders the study of the physical mechanisms behind a variety of phenomena in SLM such as splashing and balling effects, and further poses challenges to the quality control of the products. Powder-scale computational models can reproduce the multi-physics process of SLM. In this study, we couple the Finite Volume Method (FVM) and Discrete Element Method to model the deposition of powder particles, and use the FVM to model the melting process, both with ambient air. In particular, a cutting-edge sharp surface capturing technique (iso-Advector) is incorporated into the Volume of Fluid Model to reconstruct the interface between different phases during the melting process. Iso-Advector is then used to capture and reconstruct the interface between molten material and ambient air, which is further used as a solid boundary for spreading the next powder layer. As such, 3D geometrical data is exchanged between these two stages repeatedly to reproduce the powder spreading-melting process of SLM incorporating different scan paths on multiple powder layers. To demonstrate the effectiveness of the powder-scale multi-physics modeling framework, typical scenarios with different fabrication parameters (Ti-6Al-4V powder) are simulated and compared with experimental observations available in literature. [ABSTRACT FROM AUTHOR]

In this work, we propose an efficient smoothed particle hydrodynamics (SPH) method for simulating laser powder bed fusion (LPBF). The multi-physics process of LPBF, including the heat transfer and phase change with complex boundaries, is accurately resolved by a novel heat source model and a modified continuous surface force based on a corrected surface delta function. Moreover, we also develop an efficient tensile instability control algorithm for preventing the pressure oscillations. The present method is implemented in a GPU-accelerated framework, and its performance is well demonstrated by simulating the LPBF processes with both single-layer and multi-layer powder beds (with the help of surface reconstruction). The numerical results are compared well with the experimental ones which clearly verify the ability of the present method in capturing the complex physical phenomenon of LPBF. [ABSTRACT FROM AUTHOR]