• Christoph Meier, Technical University Of Munich
  • Michele Chiumenti
  • Neil E. Hodge
  • Miguel Cervera
  • Wolfgang A. Wall

Additive Manufacturing (AM) of metals aims at the production of high-performance functional parts with mechanical properties comparable to processes such as casting, milling or forging. As compared to these classical processes, however, AM offers highest production flexibility and almost unlimited freedom of design, which enables the generation of highly complex geometries or substructures (e.g. lattice-based, honeycomb-like, biomimitec designs) that cannot be obtained by conventional manufacturing processes. However, depending on the chosen process parameters, processing strategy and geometric design large thermal distortions as well as high residual stresses can result from the strongly localized energy input, which in combination with residual porosity might even induce cracking of the part already during the production process. While predictive, physics-based modeling approaches would be highly desirable for systematic process and geometry optimization, the inherent multi-scale nature of these processes still prohibits part-scale simulations with geometrically resolved heat source path. Apart from computational efficiency, also the aspect of constitutive modeling, taking into account the strongly inhomogeneous and anisotropic evolution of microstructure and resulting material properties during the process, is critical for an accurate residual stress prediction.

The purpose of this minisymposium is to provide a forum for discussion in the modeling and simulation community as applied to AM of metals. Contributions on the part-scale thermo-mechanical modeling of any relevant process (e.g., selective laser melting / sintering, electron beam melting, laser deposition welding, directed energy deposition, binder jetting, material droplet printing, etc.) are welcome. Topics of interest include, but are not limited to:
• Part-scale thermo-mechanical modeling and simulation of metal AM processes to predict residual stresses / strains, thermal distortion etc.
• Non-standard, adaptive temporal and spatial discretization strategies
• Efficient numerical schemes, solvers and algorithms (e.g., linear/nonlinear solvers, code parallelization techniques, etc.) tailored for part-scale AM simulation
• Reduced-order and phenomenological approaches for residual stress modeling
• Energy input agglomeration strategies (e.g., track/layer agglomeration)
• Thermo-mechanical material modeling (either directly on continuum level or microstructureinformed)
• Multiscale approaches considering several of the relevant time / length scales of the process
• Inverse approaches, e.g., for geometric compensation of part distortion
• Coupled process-part optimization for the design of functionally tailored / lightweight parts
• Modeling of non-standard processes, enabling 2D and 3D material activation beyond the point-by-point, line-by-line, layer-by-layer paradigm

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