Numerical approaches and validation of interface-conforming high-fidelity multiphase modeling for advanced manufacturing applications

  • Lin, Stephen (Sandia National Laboratories)
  • Hejnal, Brooke (Sandia National Laboratories)
  • Moser, Dan (Sandia National Laboratories)

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The physics of laser-metal processing technologies used in advanced manufacturing methods, such as laser powder bed fusion (LPBF) and welding, is a complex combination of radiative absorption, phase change, fluid flow, moving boundaries, surface tension, and vaporization, typically driving the formation of a cavity beneath the laser. Credible predictions of the outcomes of these technologies are challenging but can mitigate defects and poor performance of manufactured parts. The inherent multiphysics and multiscale behavior of these processes poses a numerical challenge in terms of both stability and throughput. This work presents a high-fidelity modeling approach utilizing a level set method that tracks the location of the moving interface coupled with a dynamic meshing scheme to continually conform the mesh to the gas/metal free surface. Keyhole dynamics are resolved through simplified momentum and energy flux models that capture vaporization mechanics. We will also present ongoing efforts to characterize the associated computational costs as well as strategies used to accelerate simulations through numerical and physics modifications. Validation cases to previous AM Bench challenge problems, a series of highly controlled advanced manufacturing benchmark data released by NIST, will also be presented.