Calibration of a mesoscopic simulation tool for PBF-EB by electron optical evaluation (T09#)

• Subject Area: Joining and Separation Technology
• Term: since 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 61375930

Electron beam powder bed fusion is an additive manufacturing process used for high-tech applications in aerospace or medical industry. Digital process development based on mesoscopic simulation is the key to accelerate the traditionally time-consuming process strategy development for complex parts and new materials. However, simulation tools must be calibrated and validated, since the temperature dependence of important physical variables such as energy absorption coefficient, surface tension or viscosity is mostly unknown. Metallographic analysis of simple test samples is used classically but the results are ambiguous and limited. Therefore in-situ observation of the highly dynamic melting process is necessary to capture dynamic effects resulting from the interplay of the unknown variables. The aim of this transfer project is to prove in-situ electron optical observation (ELO) for the develop-ment of a reliable calibration procedure for a sophisticated mesoscopic simulation tool of the industrial partner Arcam AB. To this end, we aim to extend multi-detector ELO to the dynamic melt pool regime. So far, multi-detector ELO is used to measure the 3D topography of solidified melt surfaces in-situ every built layer. Now, we will fully exploit the capability of the electron beam to move extremely fast to observe the 3D topography of the still liquid melt pool. A series of experiments allows to observe different melt pool regimes based on different dynamic effects and thereby to calibrate the mesoscopic simulation tool based on detailed and time dependent information. In the end, a methodology is developed which enables fast and reliable calibration and validation of mesoscopic simulation tools for new materials.

• DFG Programme: Collaborative Research Centres (Transfer Project)
• Subproject of: SFB 814: Additive Manufacturing
• International Connection: Sweden
• Applicant Institution: Friedrich-Alexander-Universität Erlangen-Nürnberg
• Business and Industry: Arcam AB
• Project Head: Professorin Dr.-Ing. Carolin Körner