COUPLED 2025

High-fidelity Thermomechanical Modeling of Laser-based Powder Bed Fusion of Metals using an Immersed Boundary Method

  • Carraturo, Massimo (University of Pavia)
  • Kopp, Philipp (Bauhaus-Universität Weimar)

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Laser-based Powder Bed Fusion of Metals (PBF-LB/M) is today’s most widespread Additive Manufacturing (AM) technology in the industry. It allows the production of almost freeform components with unprecedented design freedom. However, due to the complex physical phenomena involved in the process, process-structure-property relationships in PBF-LB/M are not yet fully understood. Therefore, validated numerical models can help researchers shed light on these complex interactions, thus leading to more reliable and effective design of functional AM parts. In the present contribution, a suitable high-fidelity thermomechanical model is developed, implemented, and tested to study the influence of complex thermal histories on the final part shape as well as to predict process-induced residual stresses in metal AM components. The multi-level hp version of the Finite Element Method is employed to achieve local refinement while an immersed boundary approach, namely the Finite Cell Method, is used to implicitly capture the material interface between air, powder, and solid material states, avoiding conform meshing. Implementation of the presented thermomechanical framework is publicly available at https://gitlab.com/hpfem/code/pbf under MIT-License, the code is also distributed as a Python library (pip install pbf).