Refined Formulations of Resolved Vapor Flow and Unresolved Recoil Pressure Models for Rapid Evaporation in Metal Additive Manufacturing under Elevated Pressure
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Laser-based powder bed fusion of metals (PBF-LB/M) enables highly optimized, complex parts for demanding applications, but process-induced defects can compromise quality and reliability. Precise computational simulations are essential to understand how these defects relate to process parameters. A major challenge in simulating PBF-LB/M is the accurate modeling of rapid evaporation dynamics. Particularly under elevated gas pressure conditions in the build chamber, currently available evaporation models exhibit limited accuracy. The most accurate predictions can be obtained using resolved vapor simulations. In this work, we present first steps towards a high-fidelity simulation framework for melt pool dynamics that resolves the compressible gas phase and incorporates thermodynamically consistent phase coupling, including non-equilibrium evaporation. In particular, we introduce a new, refined evaporation model for resolved vapor simulations under elevated pressure conditions. Building on the widely used model of Knight, we derive a kinetic-theory-based formulation that accounts for bulk motion of the liquid phase as well as the relative motion of the phase interface due to evaporative mass loss, which was not considered in the original work. The numerical approach is based on a sharp-interface cut discontinuous Galerkin (cutDG) formulation combined with a level-set method for interface tracking. Phase-coupling conditions are enforced using an explicit approximate Riemann solver, Nitsche-type weighted flux methods, and penalty-based approaches. Further, efficient matrix-free solvers implemented within the finite element library deal.II are employed. In addition, for computationally efficient free-surface flow models, we propose an iterative scheme to compute pressure-aware mass-flux and recoil-pressure boundary conditions. This approach allows to explicitly consider the atmospheric pressure in the build chamber and to yield significantly improved accuracy compared to the commonly used recoil pressure model, assuming a Mach number of one in the gas phase.
