Multi-physics modeling of powder bed fusion process and thermal stress near porosity

Abstract In this research, a novel Comprehensive Modeling Framework (CMF) was established to investigate Laser Powder Bed Fusion (L-PBF) and thermal stress formed in the process. The CMF integrates two physical modeling components: thermal-fluid model and thermal–mechanical model. As first merit, almost all the physical fundamentals, like melting, solidification, evaporation, molten pool, and thermal stress are involved in CMF. CMF’s second merit is embodied in an innovative fluid–structure interface, which can help to precisely mesh powder bed and inner pores, and accurately interpolate temperature data between two models. As validation, a single-track Ti6Al4V L-PBF case was simulated with the CMF model.