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Simulations of directed energy deposition additive manufacturing process by smoothed particle hydrodynamics methods

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Abstract

This paper presents a novel application of a three-dimensional smoothed particle hydrodynamics model to simulate directed energy deposition (DED) additive manufacturing processes. A proposed workflow comprises a random powder generator to introduce individual powder particles into the SPH core simulation. The DED workflow simulation is successfully demonstrated for two real DED setups with significantly difference of individual powder/melt-pool size ratios and different materials. The simulation results are in good agreement with experimental data in terms of geometrical dimensions of deposited material and melt-pool surface temperature. Detail analyses on the results revealed transient internal characteristics of the melt-pool which otherwise nearly impossible to be observed from experimental data. These include the concave shape of the melt-pool surface, bifurcations and circulations of metal liquid flow, and spatial–temporal temperature distributions in the melt-pool which also vary with respect to scan parameters. These findings could provide better understanding on the DED processes that are difficult to measure and help achieve better quality of the printed products.

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Availability of data and material

The data that support the findings of this study are available from the corresponding author, M.H. Dao, upon reasonable request.

Code availability

The code that supports the findings of this study is available from the corresponding author, M.H. Dao, upon reasonable request.

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Acknowledgements

Numerical simulations are performed on ASPIRE1 (Advanced Supercomputer for Petascale Innovation Research and Enterprise) provided by the National Supercomputing Centre (NSCC) Singapore.

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  1. Institute of High Performance Computing, Agency for Science, Technology and Research, 1 Fusionopolis Way, Connexis, 138632, Singapore

    My Ha Dao & Jing Lou

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  1. My Ha Dao
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  2. Jing Lou
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Correspondence to My Ha Dao.

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Dao, M.H., Lou, J. Simulations of directed energy deposition additive manufacturing process by smoothed particle hydrodynamics methods. Int J Adv Manuf Technol 120, 4755–4774 (2022). https://doi.org/10.1007/s00170-022-09050-1

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