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Many additive manufacturing (AM) technologies rely on powder feedstock, whichis fused to form the final part either by melting or by chemical binding withsubsequent sintering. In both cases, process stability and resulting partquality depend on dynamic interactions between powder particles and a fluidphase, i.e., molten metal or liquid binder. The present work proposes aversatile computational modeling framework for simulating such coupledmicrofluid-powder dynamics problems involving thermo-capillary flow andreversible phase transitions. In particular, a liquid and a gas phase areinteracting with a solid phase that consists of a substrate and mobile powderparticles while simultaneously considering temperature-dependent surfacetension and wetting effects. In case of laser-metal interactions, the effect ofrapid evaporation is incorporated through additional mechanical and thermalinterface fluxes. All phase domains are spatially discretized using smoothedparticle hydrodynamics. The method's Lagrangian nature is beneficial in thecontext of dynamically changing interface topologies. Special care is taken inthe formulation of phase transitions, which is crucial for the robustness ofthe computational scheme. While the underlying model equations are of a verygeneral nature, the proposed framework is especially suitable for the mesoscalemodeling of various AM processes. To this end, the generality and robustness ofthe computational modeling framework is demonstrated by severalapplication-motivated examples representing the specific AM processes binderjetting, material jetting, directed energy deposition, and powder bed fusion.Among others, it is shown how the dynamic impact of droplets in binder jettingor the evaporation-induced recoil pressure in powder bed fusion leads to powdermotion, distortion of the powder packing structure, and powder particleejection.

A Versatile SPH Modeling Framework for Coupled Microfluid-Powder  Dynamics in Additive Manufacturing: Binder Jetting, Material Jetting,  Directed Energy Deposition and Powder Bed Fusion