Thermal modeling of variable process parameter effects in powder bed fusion using electron beam

Purpose This study aims to develop a novel thermal modeling strategy to simulate electron beam powder bed fusion at part scale with machine-varying process parameters strategy. Single-bead and part-scale experiments and modeling were studied. Scanning strategies were described by the process controlling functions that enabled modeling. Design/methodology/approach The finite element analysis thermal model was used along with the powder bed fusion with electron beam experiments. The proposed strategy involves dividing a part into smaller sections and creating meso-scale models for each subsection. These meso-scale models take into consideration the variable process parameters, including power and velocity of the moving heat source, during part building. Subsequently, these models are integrated to perform partscale simulations, enabling more realistic predictions of thermal accumulation and resulting distortions. The model was built and validated with single-bead experiments and bulky parts with different features. Findings Single-bead experiments demonstrated an average error rate of 6%–24% for melt pool dimension prediction using the proposed meso-scale models with different scanning control functions. Part-scale simulations for three different geometries (cantilever beams with supports, bulk artifact and topology-optimized transfer arm) showed good agreement between modeled temperature changes and experimental deformation values. Originality/value This study presents a novel approach for electron beam powder bed fusion modeling that leverages meso-scale models to capture the influence of variable process parameters on part quality. This strategy offers improved accuracy for predicting part geometry and identifying potential defects, leading to a more efficient additive manufacturing process.