Modelling and analysis of process-induced properties of structures additively manufactured by laser surface cladding

Additive manufacturing (AM) technologies are emerging as one of the most promising methods for the production of almost arbitrarily complex components and workpieces. In contrast to subtractive manufacturing processes, AM is characterized by the fact that material is specifically added to the component layer by layer. The advantages over standard processes have ensured, particularly in the aerospace and automotive industries for so-called "rapid tooling" or in biomedical engineering, that AM appears to be almost indispensable in the manufacture of special and customized parts and lightweight constructions.The overall goal of this project is to simulate the fabrication of components using laser powder cladding (LPAS) to accurately predict the final contour of the additively manufactured component as well as the process-induced residual stresses and to investigate the influences of the selected process parameters and scan strategy. The basis of the simulations is a thermodynamically consistent and micromechanicsbased material model, which provides physically plausible results and data. Among other things, the physical plausibility allows the new methodology to be applied to problems in which no or limited experimental data are available to match the simulations. The incorporation of data-based methods and algorithms also enables an optimal trade-off between accuracy and computational speed, which would be impossible to achieve with classical methods. This work is in cooperation with Institute of Mechanics TU Dortmund.