Modeling and Simulation of Additively Manufactured Thin-Walled Structures

This chapter presents a comprehensive analysis of modeling and simulation strategies for additively manufactured thin-walled structures, emphasizing metallic materials. Additive manufacturing (AM), a bottom-up process, enables fabrication of complex geometries, repairs, and customizations with minimal material wastage. The chapter categorizes deposition patterns into single/multi-layer and single/multi-track schemes, fundamental to AM applications like coatings and cladding. It explores the impact of deposition geometry, such as bead height, width, aspect ratio, and dilution—on structural quality and interlayer bonding. Modeling approaches are classified into thermal models, empirical models (e.g., regression and neural networks), and finite element simulations, each aiding in the prediction of melt pool behavior and deposition characteristics. Thermal analysis investigates heat transfer dynamics, geometry of heat sources, and material-dependent properties to optimize process parameters and reduce residual stresses. The study also emphasizes simulation-based assessment of residual stresses in thin-walled structures using thermo-mechanical models and validates them through experimental techniques like X-ray and neutron diffraction. By integrating experimental data and simulation outcomes, this work guides the selection of optimal AM conditions for enhanced dimensional accuracy and mechanical integrity. The chapter serves as a foundational reference for extending AM applicability to high-melting-point and biocompatible materials in aerospace, biomedical, and manufacturing sectors.