Multiphysic Simulation of molten pool transients for electron beam welding and additive manufacturing processes investigation

Molten pool free surface shape calculation and its evaluation in time for analysis of electron beam melting and welding processes is a very important problem. Unfortunately, experimental methods can provide only a part of the necessary information. Electron beam heating creates the conditions for intense metal transfer, and pool surface shape affects the energy absorption efficiency. This paper reports the method which combines the Monte-Carlo simulation for spatial and energy parameters of heating source calculating with the Volume of Fluid algorithm for liquid free-surface numerical evaluation. The velocity and pressure field technique calculation in a molten pool with the action of surface tension forces and vapor recoil pressure is described. It is shown that the proposed simulation method allows to study heat and mass transfer transient processes, including deep penetration channel formation. Model validation was carried out. Simulation results are shown to be consistent with experimental data obtained using a high-speed camera.