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Optimization of point-melting strategies for the Electron Beam Melting process
Univ Sao Paulo, Brazil.
Linköping University, Department of Management and Engineering, Solid Mechanics. Linköping University, Faculty of Science & Engineering.
Univ Sao Paulo, Brazil.
Arcam EBM Ctr Excellence, Sweden.
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2025 (English)In: Finite elements in analysis and design (Print), ISSN 0168-874X, E-ISSN 1872-6925, Vol. 249, article id 104356Article in journal (Refereed) Published
Abstract [en]

This study proposes an optimization methodology to find optimal heat source paths for point-melting in Electron Beam Melting (EBM) Powder Bed Fusion (PBF) processes, aiming to reduce the need for support structures and improve print quality. The building process is simulated using a time-dependent, one-way coupled, non-linear thermo-mechanical model, assuming negligible molten flow, with elastoplastic behavior and temperature-dependent material parameters. The goal of the optimization problem is to find heat source paths that minimize a global temperature measure with a penalty on excessive local temperatures. The numerical methodology is based on solving the non-linear partial differential equations via the Finite Element Method (FEM) and is applied in numerical examples for printing with titanium alloy Ti6Al4V. Metrics related to heat, residual displacement, and residual stresses are considered to assess the performance of different point-melting strategies and to compare optimized and conventional paths. The feasibility of the proposed optimization methodology for practical applications and alternatives towards future methodological advancements are discussed. The study provides a Python-based, MPI-parallelized implementation using open-source libraries and is made available for further research and applications.

Place, publisher, year, edition, pages
ELSEVIER , 2025. Vol. 249, article id 104356
Keywords [en]
Additive manufacturing; Point-melting strategy; Optimization; Thermo-mechanical analysis; Finite Element Method
National Category
Applied Mechanics
Identifiers
URN: urn:nbn:se:liu:diva-214883DOI: 10.1016/j.finel.2025.104356ISI: 001503198400002Scopus ID: 2-s2.0-105006840922OAI: oai:DiVA.org:liu-214883DiVA, id: diva2:1971401
Note

Funding Agencies|Sao Paulo Research Foundation (FAPESP) [2020/14288-0, 2023/00822-2]; National Council for Scientific and Technological Development-CNPq [307679/2023-3, 304192/2019-8, 304074/2020-9, 308704/2022-3]; FAPESP [2013/07375-0]

Available from: 2025-06-17 Created: 2025-06-17 Last updated: 2025-06-17

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