Modeling and Analysis of Process-Induced Properties of Structures Additively Manufactured by Laser Metal Deposition

The objective, in cooperation with the Institute of Mechanics, is to simulate the manufacturing of components by laser metal deposition in order to predict the final contour of the manufactured component as well as the residual stresses and to investigate the influences of the selected process parameters. The basis of the simulations is a thermodynamically consistent material model based on micromechanics which provides physically plausible results and data. This plausibility enables, among other things, the application of the new methodology to problems in which no or only limited experimental data are available to validate the simulations. The incorporation of data-based methods also enables an optimal trade-off between accuracy and computation time that would not be achievable with classical methods. First, the relationship between the process parameters and the resulting weld track geometries, including the dilution zone, the resulting distortion, and the residual stresses will be investigated by means of XRD measurements.

Schewe, M., Noll, I., Bartel, T., Menzel, A., 2025. Towards the simulation of metal deposition with the Particle Finite Element Method and a phase transformation model, Computer Methods in Applied Mechanics and Engineering,

https://doi.org/10.1016/j.cma.2025.117730

Schewe, M., Bartel, T., Menzel, A., 2025. Comparison of elements and state-variable transfer methods for quasi-incompressible material behaviour in the particle finite element method, Computational Mechanics. https://doi.org/10.1007/s00466-024-02531-y