Validation experiments for LBM simulations of electron beam melting

Regina Ammer (), Ulrich Rüde (), Matthias Markl (), Vera Jüchter () and Carolin Körner ()
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Regina Ammer: Department of Computer Science 10 System Simulation, University of Erlangen-Nuremberg, Cauerstr. 11, 91058 Erlangen, Germany
Ulrich Rüde: Department of Computer Science 10 System Simulation, University of Erlangen-Nuremberg, Cauerstr. 11, 91058 Erlangen, Germany
Matthias Markl: Chair of Metals Science and Technology, University of Erlangen-Nuremberg, Martensstr. 5, 91058 Erlangen, Germany
Vera Jüchter: Chair of Metals Science and Technology, University of Erlangen-Nuremberg, Martensstr. 5, 91058 Erlangen, Germany
Carolin Körner: Chair of Metals Science and Technology, University of Erlangen-Nuremberg, Martensstr. 5, 91058 Erlangen, Germany

International Journal of Modern Physics C (IJMPC), 2014, vol. 25, issue 12, 1-9

Abstract: This paper validates three-dimensional (3D) simulation results of electron beam melting (EBM) processes by comparing experimental and numerical data. The physical setup is presented which is discretized by a 3D thermal lattice Boltzmann method (LBM). An experimental process window is used for the validation depending on the line energy injected into the metal powder bed and the scan velocity of the electron beam. In the process window, the EBM products are classified into the categories, porous, good and swelling, depending on the quality of the surface. The same parameter sets are used to generate a numerical process window. A comparison of numerical and experimental process windows shows a good agreement. This validates the EBM model and justifies simulations for future improvements of the EBM processes. In particular, numerical simulations can be used to explain future process window scenarios and find the best parameter set for a good surface quality and dense products.

Keywords: 3D thermal lattice Boltzmann method; free surface; electron beam melting; validation experiments; 11.25.Hf; 123.1K (search for similar items in EconPapers)
Date: 2014
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DOI: 10.1142/S0129183114410095

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