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This article proposes a coupled thermomechanical finite element modeltailored to the macroscale simulation of metal additive manufacturing processessuch as selective laser melting. A first focus lies on the derivation of aconsistent constitutive law on basis of a Voigt-type spatial homogenizationprocedure across the relevant phases, powder, melt and solid. The proposedconstitutive law accounts for the irreversibility of phase change andconsistently represents thermally induced residual stresses. In particular, theincorporation of a reference strain term, formulated in rate form, allows toconsistently enforce a stress-free configuration for newly solidifying materialat melt temperature. Application to elementary test cases demonstrates thevalidity of the proposed constitutive law and allows for a comparison withanalytical and reference solutions. Moreover, these elementary solidificationscenarios give detailed insights and foster understanding of basic mechanismsof residual stress generation in melting and solidification problems withlocalized, moving heat sources. As a second methodological aspect, dual mortarmesh tying strategies are proposed for the coupling of successively appliedpowder layers. This approach allows for very flexible mesh generation forcomplex geometries. As compared to collocation-type coupling schemes, e.g.,based on hanging nodes, these mortar methods enforce the coupling conditionsbetween non-matching meshes in an $L^2$-optimal manner. The combination of theproposed constitutive law and mortar mesh tying approach is validated onrealistic three-dimensional examples, representing a first step towardspart-scale predictions.

A simple yet consistent constitutive law and mortar-based layer coupling  schemes for thermomechanical macroscale simulations of metal additive  manufacturing processes