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This work proposes an extension of phase change and latent heat models forthe simulation of metal powder bed fusion additive manufacturing processes onthe macroscale and compares different models with respect to accuracy andnumerical efficiency. Specifically, a systematic formulation of phase fractionvariables is proposed relying either on temperature- or enthalpy-basedinterpolation schemes. Moreover, two well-known schemes for the numericaltreatment of latent heat, namely the apparent capacity and the so-called heatintegration scheme, are critically reviewed and compared with respect tonumerical efficiency and overall accuracy. Eventually, a novel variant of theheat integration scheme is proposed that allows to directly control efficiencyand accuracy by means of a user-defined tolerance. Depending on the chosentolerance, it is shown that this novel approach offers increased numericalefficiency for a given level of accuracy or improved accuracy for a given levelof numerical efficiency as compared to the apparent capacity and the originalheat integration scheme. The investigation and comparison of all consideredschemes is based on a series of numerical test cases that are representativefor application scenarios in metal powder bed fusion additive manufacturing.

On phase change and latent heat models in metal additive manufacturing process simulation