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In this contribution, we validate a physical model based on a transienttemperature equation (including latent heat) w.r.t. the experimental setAMB2018-02 provided within the additive manufacturing benchmark series,established at the National Institute of Standards and Technology, USA. We aimat predicting the following quantities of interest: width, depth, and length ofthe melt pool by numerical simulation and report also on the obtainablenumerical results of the cooling rate. We first assume the laser to posses adouble ellipsoidal shape and demonstrate that a well calibrated, purely thermalmodel based on isotropic thermal conductivity is able to predict all thequantities of interest, up to a deviation of maximum 7.3\% from theexperimentally measured values.  However, it is interesting to observe that if we directly introduce, wheneveravailable, the measured laser profile in the model (instead of the doubleellipsoidal shape) the investigated model returns a deviation of 19.3\% fromthe experimental values. This motivates a model update by introducinganisotropic conductivity, which is intended to be a simplistic model for heatmaterial convection inside the melt pool. Such an anisotropic model enables theprediction of all quantities of interest mentioned above with a maximumdeviation from the experimental values of 6.5\%.  We note that, although more predictive, the anisotropic model induces only amarginal increase in computational complexity.

integrating materials and manufacturing innovation

Accurate prediction of melt pool shapes in laser powder bed fusion by  the non-linear temperature equation including phase changes - isotropic  versus anisotropic conductivity