A REVIEW OF THERMAL MODELLING FOR METAL ADDITIVE MANUFACTURING PROCESSES: BASIC ANALYTICAL MODELS TO STATE-OF-THE-ART SOFTWARE PACKAGES.

This contribution will review computer modelling of metal Additive Manufacturing processes that involve a moving point heat source, with attention given to powder bed fusion . Modelling AM processes is important; because it allows AM practitioners to enhance understanding and will help improve the process at the planning stage of the manufacturing process. Full thermal modelling of PBF processes is a significant challenge but it will facilitate improved prediction of levels of porosity and the formation of microstructures. Thermal history of a part is the starting point for a residual stress analysis and therefore imperative. Advancements have been made in modelling approaches, evolving from Rosenthal’s basic analytical model progressing into Goldak’s continuum model. Initially considered in a welding context, these two basic models are adaptable and are commonly used for laser heating processes. DIABLO, a continuum thermomechanical model associated with the Lawrence Livermore National Laboratory, is reviewed. The significance of powder bed models and fluid flow in the melt pool, particularly Marangoni convection, will be investigated within the literature. Presently the market offers several commercial software packages for AM, including packages offered by ANSYS, COMSOL and MSC. State-of-the art software packages will be reviewed by comparing their specific claims and investigating those claims where possible.