High-fidelity part-scale simulations in metal additive manufacturing using a computationally efficient and accurate approach

This paper introduces a novel local–global thermo-mechanical simulation method based on the Virtual Domain Approximation (VDA) to enhance part-scale analysis in Direct Energy Deposition (DED), a prominent Metal Additive Manufacturing (MAM) technique. DED offers transformative capabilities in the production of complex metal components by enabling precise, layer-by-layer deposition of material using focused energy sources such as lasers or electron beams. However, its widespread adoption remains hindered by challenges such as accurate prediction of material behavior, complex thermal gradients, and residual stresses inherent to the DED process. Conventional experimental approaches are not only expensive but also limited in exploring the wide range of process parameters typical of DED, highlighting the need for efficient numerical simulations for component qualification.

Our proposed simulation framework significantly improves computational efficiency without sacrificing accuracy, addressing the resource-intensive nature of High-Fidelity (HF) simulations. By adopting a local–global strategy, the size of the numerical domain is reduced to a region of interest close to the Heat-Affected Zone (HAZ). This paper details the local–global approach criterion and the application of a residual-based VDA for the approximation of the boundary condition of the local domain. A comparative evaluation against standard finite element (FE) full-order simulations underscores the advantages of our approach in accurately speeding-up the mechanical simulation.

This research provides a powerful tool for efficient and accurate simulations, advancing DED technology within the broader MAM framework and supporting its wider implementation across industries such as aerospace, automotive, and energy.