A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion Method
Metal additive manufacturing (AM) has grown in recent years to supplement or even replace traditional fabrication methods. Specifically, the laser powder bed fusion (LPBF) process has been used to manufacture components in support of sustainment issues, where obsolete components are hard to procure....
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MDPI AG
2025-01-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/1/22 |
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| author | Emmanuel De Leon Alex Riensche Benjamin D. Bevans Christopher Billings Zahed Siddique Yingtao Liu |
| author_facet | Emmanuel De Leon Alex Riensche Benjamin D. Bevans Christopher Billings Zahed Siddique Yingtao Liu |
| author_sort | Emmanuel De Leon |
| collection | DOAJ |
| description | Metal additive manufacturing (AM) has grown in recent years to supplement or even replace traditional fabrication methods. Specifically, the laser powder bed fusion (LPBF) process has been used to manufacture components in support of sustainment issues, where obsolete components are hard to procure. While LPBF can be used to solve these issues, much work is still required to fully understand the metal AM technology to determine its usefulness as a reliable manufacturing process. Due to the complex physical mechanisms involved in the multiscale problem of LPBF, repeatability is often difficult to achieve and consequently makes meeting qualification requirements challenging. The purpose of this work is to provide a review of the physics of metal AM at the melt pool and part scales, thermomechanical simulation methods, as well as the available commercial software used for finite element analysis and computational fluid dynamics modeling. In addition, metal AM process qualification frameworks are briefly discussed in the context of the computational basis established in this work. |
| format | Article |
| id | doaj-art-e38ea12bd69c4ed0afbcf92e2a7416f6 |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-e38ea12bd69c4ed0afbcf92e2a7416f62025-01-24T13:36:28ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-01-01912210.3390/jmmp9010022A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion MethodEmmanuel De Leon0Alex Riensche1Benjamin D. Bevans2Christopher Billings3Zahed Siddique4Yingtao Liu5Sooner Advanced Manufacturing Laboratory, The University of Oklahoma, Norman, OK 73019, USASooner Advanced Manufacturing Laboratory, The University of Oklahoma, Norman, OK 73019, USASooner Advanced Manufacturing Laboratory, The University of Oklahoma, Norman, OK 73019, USASooner Advanced Manufacturing Laboratory, The University of Oklahoma, Norman, OK 73019, USASooner Advanced Manufacturing Laboratory, The University of Oklahoma, Norman, OK 73019, USASooner Advanced Manufacturing Laboratory, The University of Oklahoma, Norman, OK 73019, USAMetal additive manufacturing (AM) has grown in recent years to supplement or even replace traditional fabrication methods. Specifically, the laser powder bed fusion (LPBF) process has been used to manufacture components in support of sustainment issues, where obsolete components are hard to procure. While LPBF can be used to solve these issues, much work is still required to fully understand the metal AM technology to determine its usefulness as a reliable manufacturing process. Due to the complex physical mechanisms involved in the multiscale problem of LPBF, repeatability is often difficult to achieve and consequently makes meeting qualification requirements challenging. The purpose of this work is to provide a review of the physics of metal AM at the melt pool and part scales, thermomechanical simulation methods, as well as the available commercial software used for finite element analysis and computational fluid dynamics modeling. In addition, metal AM process qualification frameworks are briefly discussed in the context of the computational basis established in this work.https://www.mdpi.com/2504-4494/9/1/22metal additive manufacturingmultiscale physicsprocess simulationmultiscale simulationprocess qualificationlaser powder bed fusion |
| spellingShingle | Emmanuel De Leon Alex Riensche Benjamin D. Bevans Christopher Billings Zahed Siddique Yingtao Liu A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion Method Journal of Manufacturing and Materials Processing metal additive manufacturing multiscale physics process simulation multiscale simulation process qualification laser powder bed fusion |
| title | A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion Method |
| title_full | A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion Method |
| title_fullStr | A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion Method |
| title_full_unstemmed | A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion Method |
| title_short | A Review of Modeling, Simulation, and Process Qualification of Additively Manufactured Metal Components via the Laser Powder Bed Fusion Method |
| title_sort | review of modeling simulation and process qualification of additively manufactured metal components via the laser powder bed fusion method |
| topic | metal additive manufacturing multiscale physics process simulation multiscale simulation process qualification laser powder bed fusion |
| url | https://www.mdpi.com/2504-4494/9/1/22 |
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