Component scale process model for metal additive manufacturing

Producing components for applications requiring extreme performance and part quality can be troublesome for selective laser melting (SLM). To combat these challenges it is essential to know how process parameters ultimately affect the properties of the product. It is also true that at present it is almost impossible to react on-line if process monitoring indicates that process anomalies have occurred, let alone establish build specific optimal parameters, primarily due to the intrinsic complexities of the manufacturing process. As a solution a thermomechanical process model and a multiscale modelling concept for SLM are presented. With the model it is possible to simulate the effect of different process parameters and also to test how to compensate the anomalies in the following build layers. Capability to tackle realistic part geometries is introduced by interfacing the model to SLM machine build and process files. The modelling toolset can be used in predicting distortions, residual stresses and porosity in the produced component. It can also be used as a tool in the component design phase to set process parameters and complete the actual design in such a way that minimises distortions, porosity or unfavourable microstructural phases, as well as investigate and in the future optimise support structure generation.