WENTAO YAN, PhD, is a Tenured Associate Professor in the Department of Mechanical Engineering at the National University of Singapore (NUS). Since 2014, he has been working on multi-scale multi-physics modeling, experimental investigation and data analysis of additive manufacturing. He has published >140 papers on flagship journals and his team was the winner in the 2022 NIST AM Bench Simulation Challenges, winning 9 awards in 25 tests.

YANMING ZHANG, PhD, is a Research Fellow in the Department of Mechanical Engineering at NUS. His research focuses on the multiphase flow modeling of multi-material additive manufacturing.

DAIJUN HU, PhD, is a Research Fellow in the Department of Mechanical Engineering at NUS. His research focuses on residual stress, dislocation dynamics and fracture, providing mechanistic insights into material behavior through computational modeling of additive manufacturing.

YUHAN JU is a PhD candidate in the Department of Mechanical Engineering at NUS. Her research focuses on the modeling of microstructure evolutions in additive manufacturing at grain and dendrite scales with the phase-field and cellular automaton methods.

YIMING LIU is a PhD student under the Integrative Sciences and Engineering Programme at NUS. His research focuses on data-driven modeling, diagnostics and close-loop control in additive manufacturing.

Preface xi
Acknowledgments xv
Acronyms xvii

1 Introduction 1

2 Modeling of Powder Dynamics 5
2.1 Introduction 5
2.2 Methodology 6
2.3 Experimental Validation 13
2.4 Modeling of Powder Spreading in Powder-bed-based Additive Manufacturing 15
2.5 Modeling of Powder Feeding in Powder-feed Directed Energy Deposition 26
2.6 Modeling of Spattering in Laser Powder Bed Fusion 30
2.7 Summary 36

3 Modeling of Melt Pool Dynamics 39
3.1 Introduction 39
3.2 Methodology 41
3.3 Simulation of Single-material PBF Process 80
3.4 Simulation of Multi-material PBF Process 107
3.5 Simulation of AM Process Under External Fields 140
3.6 Summary 156

4 Modeling of Microstructure Evolutions 159
4.1 Introduction 159
4.2 Modeling of Grain Evolutions 160
4.3 Modeling of Dendrite Evolutions 178
4.4 Modeling of Precipitation 212
4.5 Summary 229

5 Modeling of Thermal/Residual Stresses 231
5.1 Introduction 231
5.2 Experimental Validation 235
5.3 Microscale Model of Thermal/Residual Stresses 237
5.4 Mesoscale Model of Thermal/Residual Stresses 256
5.5 Macroscale Model of Thermal/Residual Stresses 268
5.6 Model of Dislocation Evolution Driven by Thermal Stresses 277
5.7 Model of DRX Driven by Thermal Stresses 291
5.8 Summary 296

6 Modeling of Mechanical Properties of Additively Manufactured Materials 299
6.1 Introduction 299
6.2 Methodology 300
6.3 Modeling of Mechanical Properties of AM AlSi10Mg: Room-and High-temperature 303
6.4 Strain Localization in Additively Manufactured Material 314
6.5 Fracture and Fatigue Modeling in AM Materials 332
6.6 Summary 345

7 Data-driven Modeling and Analysis 347
7.1 Introduction 347
7.2 Data Foundations and Modeling Workflow for AM 348
7.3 Statistical Methods for Data-driven Analysis 349
7.4 Data-driven Surrogate Modeling 354
7.5 Uncertainty Quantification 383
7.6 Summary 392

8 Synergy of Modeling with Other Techniques 393
8.1 Introduction 393
8.2 Data Collection 395
8.3 Data Handling and Preprocessing 398
8.4 Digital Twin for AM 408
8.5 Toward Closed-loop Control 412
8.6 Summary 416

References 417
Index 473