Numerical Simulation and Data-Driven Modeling of Metallic Materials Formed by Laser Additive Manufacturing

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (30 September 2024) | Viewed by 2164

Special Issue Editors


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Guest Editor
School of Materials Science and Engineering, Shanghai University, Shanghai 200444, China
Interests: laser additive manufacturing; microstructure control; superalloy

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Shanghai University, Shanghai 200444, China
Interests: computational fluid dynamics; solidification modeling; machine learning

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) is well known for its rapid integrated forming ability for complex geometry, and as the AM industry flourishes, it is receiving increasing attention. Unlike traditional casting and other forming techniques, AM involves a rapid nonequilibrium melting and solidification process, which occasionally generates defects, such as pores, deformation, cracks, etc.

Even though significant research and experiments on various alloy systems and AM processes have been carried out to study melting and solidification behavior, some mechanisms remain unclear. In this context, numerical simulation and data-driven/physics-informed machine learning modeling are important approaches to computing the dynamic evolution of multiphysics fields or establishing relationships between process, microstructures, and mechanical properties.

These approaches can help us understand the fundamental principles and rules of AM processes and provide guidance for optimizing these processes and improving product quality.

For this Special Issue, we welcome original research and review articles that focus on the following topics:

  • Numerical simulation of the multiphysics multiscale AM process, including molten pool dynamics, solidification microstructures in grain and dendrite scales, etc.;
  • Numerical simulation of the gas atomization process for powder preparation;
  • Data-driven/physics-informed machine learning modeling for predicting and optimizing AM processes;
  • Development of computation methods, such as discrete element method, the volume of fluids/level set method, cellular automata, phase field, surrogate modeling, structure optimizations, etc.

Dr. Chaoyue Chen
Dr. Songzhe Xu
Guest Editors

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Keywords

  • additive manufacturing
  • numerical simulation
  • machine learning
  • molten pool dynamics
  • solidification microstructures
  • powder preparation
  • multiphysics/multiscale modeling

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Published Papers (1 paper)

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Research

18 pages, 13604 KiB  
Article
Numerical Simulation of Gas Atomization and Powder Flowability for Metallic Additive Manufacturing
by Yonglong Du, Xin Liu, Songzhe Xu, Enxiang Fan, Lixiao Zhao, Chaoyue Chen and Zhongming Ren
Metals 2024, 14(10), 1124; https://doi.org/10.3390/met14101124 - 2 Oct 2024
Cited by 1 | Viewed by 1793
Abstract
The quality of metal powder is essential in additive manufacturing (AM). The defects and mechanical properties of alloy parts manufactured through AM are significantly influenced by the particle size, sphericity, and flowability of the metal powder. Gas atomization (GA) technology is a widely [...] Read more.
The quality of metal powder is essential in additive manufacturing (AM). The defects and mechanical properties of alloy parts manufactured through AM are significantly influenced by the particle size, sphericity, and flowability of the metal powder. Gas atomization (GA) technology is a widely used method for producing metal powders due to its high efficiency and cost-effectiveness. In this work, a multi-phase numerical model is developed to compute the alloy liquid breaking in the GA process by capturing the gas–liquid interface using the Coupled Level Set and Volume-of-Fluid (CLSVOF) method and the realizable k-ε turbulence model. A GA experiment is carried out, and a statistical comparison between the particle-size distributions obtained from the simulation and GA experiment shows that the relative errors of the cumulative frequency for the particle sizes sampled in two regions of the GA chamber are 5.28% and 5.39%, respectively. The mechanism of powder formation is discussed based on the numerical results. In addition, a discrete element model (DEM) is developed to compute the powder flowability by simulating a Hall flow experiment using the particle-size distribution obtained from the GA experiment. The relative error of the time that finishes the Hall flow in the simulation and experiment is obtained to be 1.9%. Full article
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