About the case study
This document will help you run your first AM PravaH LPBF simulation for macroscale and microstructure modeling. The case study is done for a standard alloy of titanium i.e. Ti6Al4V widely used for aerospace and biomedical applications. The simulation is carried out for a multilayer, multi-track scan pattern. The process parameters for the laser are e.g. 300 W power and e.g. 1 m/s scan speed. D4 sigma or spot dia is 0.1 mm.
Exclusive features of AM PravaH include consideration of 4 phases, with no explicit formulation for recoil pressure because evaporation and recoil pressure effects are included in the vapor phase. AM PravaH takes the thermophysical properties of the 4 phases as inputs along with the process parameters such as laser power, laser scan speed, shielding gas flow angle and velocity, layer thickness, spot diameter, preheating temperature, chamber initial pressure, and substrate initial height, scan pattern, particle size distribution and number of layers. Macroscale modeling will generate the following outputs melt pool dimensions, porosity %, thermal gradients, cooling rates, and thermal cycling plots. The Microstructure module generates outputs such as grain size distribution, angular chord length distribution, misorientation angles, and Euler angles. AM PravaH leverages the amalgamation of computational modeling solvers performing multiphase macroscale modeling, microstructure modeling, and Artificial Intelligence (AI) at a unified platform.
Keywords: Additive Manufacturing, 3D printing, Meltpool dynamics, porosity, thermal gradients, cooling rate, microstructure analysis, grain size, angular chord length, 3D printing software
AM PravaH: 3D printing simulation software
Introduction
AM PravaH is a 3D printing simulation software that facilitates end-to-end solutions for Additive Manufacturing physics-based simulations. Additive Manufacturing is commonly known as 3D printing. This 3D printing software is the “World’s first all-inclusive 3D computational software for Additive Manufacturing”. This 3D printing software will be useful for new alloy development, process parameter optimization, and reducing defects. Not to confuse with other 3D printing software that only performs thermomechanical analysis and deformation, AM PravaH software offers much more.
The software capabilities in brief are as follows:
There are three modules in AM PravaH
(i) Macroscale modeling
(ii) Microstructure analysis
(iii) Integrated Deep Learning (AI) module
Relevance of the 3D printing software; AM PravaH
This 3D printing software is relevant for researchers, academicians, and industry professionals from large and small-sized companies working in the Additive Manufacturing field. Where the primary focus is to understand the in-depth physics, microstructures, and effect of process parameters on the melt pool dynamics and distribution and the root cause of the defects. If we have a much closer look at the fundamental processes of 3D printing; this is a transient, very quick, and very dynamic process, which can’t be captured with the naked eye. Therefore, AM PravaH simulations can be extremely useful in understanding this part.
Based on that, one makes important decisions such as
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Which alloy is better?
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How do we get solidification, melting, and cooling rates information?
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what are the best operating process conditions to get a defect-free and dense part
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What do the microstructures look like?
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What are the grain distribution and mean grain size?
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What are the melt pool sizes?
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How much will be the porosity %?
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