Efficient part-scale thermal modeling of laser powder bed fusion via a multilevel finite element framework

IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
S.M. Elahi, J.P. Leonor, R.Y. Wu, G.J. Wagner
{"title":"Efficient part-scale thermal modeling of laser powder bed fusion via a multilevel finite element framework","authors":"S.M. Elahi,&nbsp;J.P. Leonor,&nbsp;R.Y. Wu,&nbsp;G.J. Wagner","doi":"10.1016/j.addma.2025.104897","DOIUrl":null,"url":null,"abstract":"<div><div>In this work, we show that a multilevel finite element algorithm previously demonstrated for linear problems can, using a novel time integration method and other improvements, give efficient and accurate part-scale simulations of real additive manufacturing processes. The GPU-optimized multilevel finite element framework (GO-MELT) uses multiple moving meshes to simulate thermal behavior in laser powder bed fusion (LPBF) processes; fixed mesh sizes and data structures allow straightforward implementation of this algorithm on GPU hardware. Building on this framework, we introduce key advancements including G-code parsing for complex laser paths, temperature-dependent material properties with distinct definitions for powder, solid, and fluid states, and time step subcycling across levels to manage computational loads effectively. These improvements enable precise simulation across the different material states encountered in LPBF while minimizing computational cost. Verification studies show that first-order time convergence is preserved even in the presence of nonlinearities, and the fidelity of the enhanced framework is validated against well-established experimental benchmarks, including in-situ X-ray diffraction data for Hastelloy-X and time above melting measurements from the NIST AM-Bench cantilever model. Computational tests demonstrate that our approach achieves an average execution time of 1.8 ms per time step, enabling a high-fidelity thermal simulation of 350 million time steps to be solved on a single GPU in 7.3 days, comparable to published simulations on much larger parallel systems. An analysis of thermal decay times can be used to further reduce simulation time by limiting simulation to time-points of interest. These results underscore the potential of this algorithm for advancing real-time process optimization and part quality improvement in LPBF.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104897"},"PeriodicalIF":11.1000,"publicationDate":"2025-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Additive manufacturing","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2214860425002611","RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0

Abstract

In this work, we show that a multilevel finite element algorithm previously demonstrated for linear problems can, using a novel time integration method and other improvements, give efficient and accurate part-scale simulations of real additive manufacturing processes. The GPU-optimized multilevel finite element framework (GO-MELT) uses multiple moving meshes to simulate thermal behavior in laser powder bed fusion (LPBF) processes; fixed mesh sizes and data structures allow straightforward implementation of this algorithm on GPU hardware. Building on this framework, we introduce key advancements including G-code parsing for complex laser paths, temperature-dependent material properties with distinct definitions for powder, solid, and fluid states, and time step subcycling across levels to manage computational loads effectively. These improvements enable precise simulation across the different material states encountered in LPBF while minimizing computational cost. Verification studies show that first-order time convergence is preserved even in the presence of nonlinearities, and the fidelity of the enhanced framework is validated against well-established experimental benchmarks, including in-situ X-ray diffraction data for Hastelloy-X and time above melting measurements from the NIST AM-Bench cantilever model. Computational tests demonstrate that our approach achieves an average execution time of 1.8 ms per time step, enabling a high-fidelity thermal simulation of 350 million time steps to be solved on a single GPU in 7.3 days, comparable to published simulations on much larger parallel systems. An analysis of thermal decay times can be used to further reduce simulation time by limiting simulation to time-points of interest. These results underscore the potential of this algorithm for advancing real-time process optimization and part quality improvement in LPBF.
基于多层有限元框架的激光粉末床熔合的局部尺度热模拟
在这项工作中,我们证明了先前用于线性问题的多层有限元算法可以使用新的时间积分方法和其他改进,给出真实增材制造过程的有效和准确的部分尺度模拟。基于gpu优化的多层有限元框架(GO-MELT)使用多个移动网格来模拟激光粉末床熔合(LPBF)过程中的热行为;固定的网格大小和数据结构允许在GPU硬件上直接实现该算法。在此框架的基础上,我们介绍了关键的进展,包括复杂激光路径的g代码解析,对粉末,固体和流体状态具有不同定义的温度相关材料特性,以及跨级别的时间步长子循环,以有效地管理计算负载。这些改进使LPBF中遇到的不同材料状态的精确模拟成为可能,同时最大限度地降低了计算成本。验证研究表明,即使在非线性存在的情况下,一阶时间收敛性仍然保持不变,并且增强框架的保真度通过完善的实验基准进行了验证,包括哈氏合金x射线的原位x射线衍射数据和NIST AM-Bench悬臂模型的熔化以上时间测量。计算测试表明,我们的方法实现了每个时间步1.8 ms的平均执行时间,从而可以在7.3天内在单个GPU上解决3.5亿个时间步的高保真热模拟,与在更大的并行系统上发布的模拟相当。热衰减时间的分析可以通过将模拟限制在感兴趣的时间点来进一步减少模拟时间。这些结果强调了该算法在推进LPBF实时工艺优化和零件质量改进方面的潜力。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
求助全文
约1分钟内获得全文 求助全文
来源期刊
Additive manufacturing
Additive manufacturing Materials Science-General Materials Science
CiteScore
19.80
自引率
12.70%
发文量
648
审稿时长
35 days
期刊介绍: Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
确定
请完成安全验证×
copy
已复制链接
快去分享给好友吧!
我知道了
右上角分享
点击右上角分享
0
联系我们:info@booksci.cn Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。 Copyright © 2023 布克学术 All rights reserved.
京ICP备2023020795号-1
ghs 京公网安备 11010802042870号
Book学术文献互助
Book学术文献互助群
群 号:604180095
Book学术官方微信