Thermo-microstructural-mechanical model for precision AM and secondary processing

Process knowledge from WP2 partners and measurements from WP3 partners are used for setting up simulations and for calibrating the numerical process models. A coupled multi-scale thermo-metallurgical-mechanical model for simulating precision additive manufacturing is developed by using a local model for simulating laser-material interaction and melting/solidification processes and a global thermo-mechanical model for evaluating residual stresses and deformations. Smart, advanced modelling techniques to reduce computation time to an acceptable range while preserving accuracy are implemented and statistical methods for a robust calibration of the numerical models are applied. In addition, a thermo-microstructural-mechanical model of secondary processing of PAM^2 parts is developed through fast and accurate thermal, microstructural and mechanical solvers capable of handling large computational domains. The evolution of part porosities and resulting material properties is tracked by a developed thermal-microstructural model and constitutive modelling of materials to predict residual stresses and deformations is implemented.