Simulation and Its Use in Additive Manufacturing

Abstract

Additive manufacturing (AM) of metals is a complex process considering its fundamental physical and mechanical aspects. Understanding the processes is challenging as they are affected by many factors, so they are experimentally expensive and time consuming to study. Simulation has been identified as an important tool to overcome this challenge. The focus of this chapter is on laser-based powder diffusion (L-PBF) and controlled energy coating Direct Energy Deposition (DED) metal AM processes. Different simulations can be incorporated at each stage of the metal AM process depending on the scenario. Design for Additive Manufacturing (DfAM) is an area where simulation can be a key accessory in optimizing the design of a manufactured part. This chapter presents the use of simulation in DfAM, the different simulation software currently in use, and simulation types based on the length scale and the stage of the metal AM process. Case studies introduce various multi-scale simulations performed on industrial components. They provide a clear idea of the use and potential of simulation in the AM field.