A Highly Efficient Computational Approach for Fast Scan-Resolved Simulations of Metal Additive Manufacturing Processes on the Scale of Real Parts

This article proposes a novel high-performance computing approach for the prediction of the temperature field in powder bed fusion (PBF) additive manufacturing (AM) processes. In contrast to many existing approaches to part-scale simulations, the underlying computational model consistently resolves physical scan tracks without additional heat source scaling, agglomeration strategies or any other heuristic modeling assumptions. A growing, adaptively refined mesh accurately captures all details of the laser beam motion. Critically, the fine spatial resolution required for resolved scan tracks in combination with the high scan velocities underlying these processes mandates the use of comparatively small time steps to resolve the underlying physics. Explicit time integration schemes are well-suited for this setting, while unconditionally stable implicit time integration schemes are employed for the interlayer cool down phase governed by significantly larger time scales. These two schemes are combined and implemented in an efficient fast operator evaluation framework providing significant performance gains and optimization opportunities. The capabilities of the novel framework are demonstrated through realistic AM examples on the centimeter scale including the first scan-resolved simulation of the entire NIST AM Benchmark cantilever specimen, with a computation time of less than one day. Apart from physical insights gained through these simulation examples, also numerical aspects are thoroughly studied on basis of weak and strong parallel scaling tests. As potential applications, the proposed thermal PBF simulation approach can serve as a basis for microstructure and thermo-mechanical predictions on the part-scale, but also to assess the influence of scan pattern and part geometry on melt pool shape and temperature, which are important indicators for well-known process instabilities.