A survey of finite element analysis of temperature and thermal stress fields in powder bed fusion Additive Manufacturing

Abstract

This survey aims to provide a review on the application of finite element method to optimize process parameters and improve the mechanical performance of a part fabricated by powder-bed-fusion Additive Manufacturing process. The state-of-the-art finite element models in the simulation of powder bed fusion process are reviewed. Numerical modeling methodologies of the laser beam melting or electron beam melting process at the macro-level are summarized in detail. Specifically, the importance of pre-processing of the part model, process parameters, mesh scheme, and temperature-dependent material properties are clarified. Simulation techniques used to reduce the computational cost are also discussed. Then the existing finite element models in the simulation of powder-bed fusion processes are reviewed and discussed. Simulation results are classified based on the characteristics of the melt pool and the printed part. Then the simulation results are validated by the experiment results. Finally, the significance of finite element method in the connection of other Additive Manufacturing issues such as material design, in-process monitoring and control, and process optimization are explained. The drawbacks of existing finite element models are summarized. And potential new methods to optimize process parameters of PBF process are proposed.