Modeling Study of Porosity’s Effect on Grain Evolution During Directed Energy Deposition

Abstract In this work, porosity’s influence on grain evolution during Directed Energy Deposition was studied with the developed Kinetic Monte Carlo model. In the first case, grain evolution was simulated in a purely solid domain without any porosity. In the second case, some internal spheres were inlaid in the simulation domain as internal pores. The porosity’s effect on grain evolution was investigated by comparing the predicted grain morphologies in both cases. This study is the first work focused on porosity’s influence on additive manufacturing microstructure.