Moges Tesfaye, Ameta Gaurav, Witherell Paul
Engineering Laboratory, National Institute of Standards and Technology, Gaithersburg, MD 20899.
J Manuf Sci Eng. 2019;141. doi: 10.1115/1.4042789.
This paper presents a comprehensive review on the sources of model inaccuracy and parameter uncertainty in metal laser powder bed fusion (L-PBF) process. Metal additive manufacturing (AM) involves multiple physical phenomena and parameters that potentially affect the quality of the final part. To capture the dynamics and complexity of heat and phase transformations that exist in the metal L-PBF process, computational models and simulations ranging from low to high fidelity have been developed. Since it is difficult to incorporate all the physical phenomena encountered in the L-PBF process, computational models rely on assumptions that may neglect or simplify some physics of the process. Modeling assumptions and uncertainty play significant role in the predictive accuracy of such L-PBF models. In this study, sources of modeling inaccuracy at different stages of the process from powder bed formation to melting and solidification are reviewed. The sources of parameter uncertainty related to material properties and process parameters are also reviewed. The aim of this review is to support the development of an approach to quantify these sources of uncertainty in L-PBF models in the future. The quantification of uncertainty sources is necessary for understanding the tradeoffs in model fidelity and guiding the selection of a model suitable for its intended purpose.
本文对金属激光粉末床熔融（L-PBF）工艺中模型不准确和参数不确定性的来源进行了全面综述。金属增材制造（AM）涉及多种物理现象和参数，这些都可能影响最终零件的质量。为了捕捉金属L-PBF工艺中存在的热和相变的动态过程及复杂性，已经开发了从低保真度到高保真度的计算模型和模拟。由于难以纳入L-PBF工艺中遇到的所有物理现象，计算模型依赖于可能忽略或简化该工艺某些物理过程的假设。建模假设和不确定性在这类L-PBF模型的预测精度中起着重要作用。在本研究中，对从粉末床形成到熔化和凝固的工艺不同阶段的建模不准确来源进行了综述。还综述了与材料特性和工艺参数相关的参数不确定性来源。本综述的目的是为未来开发一种量化L-PBF模型中这些不确定性来源的方法提供支持。不确定性来源的量化对于理解模型保真度的权衡以及指导选择适合其预期目的的模型是必要的。
