The Numerical Simulation research group focuses on fundamental and application-oriented research in additive manufacturing, with a particular emphasis on Electron Beam Powder Bed Fusion (PBF-EB). The group’s work makes a visible international contribution to the advancement of this technology and is positioned among the leading research efforts worldwide in this field. Central to the research is the development of physically sound simulation approaches that enable a deep understanding of the highly dynamic phenomena occurring during the manufacturing process and open new pathways for targeted process and materials design.

Purely experimental approaches in additive manufacturing quickly encounter fundamental limitations. Key process quantities such as local temperature fields, highly time-resolved thermal cycles, or solidification conditions are only accessible to a limited extent or not directly measurable at all. At the same time, systematic experimental parameter studies are often associated with considerable effort and cost. Against this background, numerical simulation constitutes the primary scientific instrument of the research group, providing access to critical process mechanisms with high spatial and temporal resolution.

The group develops and extends proprietary simulation models and methodological tools that go beyond established standard approaches and actively contribute to the advancement of simulation technology in additive manufacturing. These models enable the quantitative prediction of thermal fields, process dynamics, and microstructural evolution as a function of beam guidance, scan strategy, component geometry, and material properties. In this way, complex interactions within the PBF-EB process become systematically accessible, allowing novel process strategies to be designed and evaluated virtually prior to experimental implementation.

A core principle of the research is the tight coupling of simulation and experiment. Experimental observations are used to validate and parameterize the numerical models, while simulation-based insights directly inform new experimental questions, measurement concepts, and process variants. This reciprocal interaction enables highly targeted experimental investigations and significantly accelerates the generation of scientific insight beyond purely empirical approaches.

Furthermore, numerical simulation provides a key link to alloy development. Detailed analyses of temperature–time histories, cooling rates, and thermal cycling yield essential information on solidification conditions and microstructural evolution. On this basis, alloys can be specifically adapted to the boundary conditions of additive manufacturing processes, and new, material-specific process windows can be established. In this way, the research group contributes not only to process development but also to the materials-driven advancement of additive manufacturing technologies.

Simulation-based process strategies

In-situ microstructure engineering

Electron optical analysis

Numerical alloy development

Dr.-Ing. Matthias Markl	Email: matthias.markl@fau.de
Dr.-Ing. Benjamin Wahlmann	Email: benjamin.wahlmann@fau.de
Jonas Böhm	Email: jonas.boehm@fau.de
Tobias Kupfer	Email: tobias.kupfer@fau.de
Dominik Leidel	Email: dominik.leidel@fau.de
Lukas Petersen	Email: lukas.petersen@fau.de
Jonas Plewinski	Email: jonas.plewinski@fau.de
Alexander Rausch	Email: alex.rausch@fau.de

Böhm J., Markl M., Körner C.:
High-throughput numerical exploration of preheating and sintering in electron beam powder bed fusion
In: Thermal Science and Engineering Progress 69 (2026), Article No.: 104405
ISSN: 2451-9057
DOI: 10.1016/j.tsep.2025.104405
Breuning C., Renner J., Markl M., Körner C.:
Processing Strategies for Electron Beam Based Powder Bed Fusion
In: Dietmar Drummer, Michael Schmidt (ed.): Progress in Powder Based Additive Manufacturing, Springer Nature, 2025, p. 127-148 (Springer Tracts in Additive Manufacturing, Vol.Part F386)
DOI: 10.1007/978-3-031-78350-0_7
Jaksch A., Cholewa S., Bartels D., Markl M., Drummer D.:
Introduction to Powder and Beam Based Additive Manufacturing
In: Progress in Powder Based Additive Manufacturing, Cham: Springer, 2025, p. 1-11 (Springer Tracts in Additive Manufacturing, Vol.Part F386)
ISBN: 9783031783494
DOI: 10.1007/978-3-031-78350-0_1
Kupfer T., Leimbach S., Spano L., Pohl S., Körner C., Markl M.:
Spot melting sequences for complex geometries in electron beam powder bed fusion
In: Progress in Additive Manufacturing (2025)
ISSN: 2363-9512
DOI: 10.1007/s40964-025-01251-w
Kupfer T., Spano L., Pohl S., Körner C., Markl M.:
Spot Melting Strategy for Contour Melting in Electron Beam Powder Bed Fusion
In: Journal of Manufacturing and Materials Processing 9 (2025), p. 303
ISSN: 2504-4494
Scherr R., Hirschfelder T., Markl M., Körner C.:
Simulation-driven development of in-situ alloying Cu-25Cr by electron beam powder bed fusion
In: Additive Manufacturing 109 (2025), Article No.: 104874
ISSN: 2214-7810
DOI: 10.1016/j.addma.2025.104874
Yang Z., Herrnböck L., Markl M., Mergheim J., Steinmann P., Körner C.:
Mesoscopic Modeling and Simulation of Properties of Additively Manufactured Metallic Parts
In: Dietmar Drummer, Michael Schmidt (ed.): Progress in Powder Based Additive Manufacturing, Springer Nature, 2025, p. 309-330 (Springer Tracts in Additive Manufacturing, Vol.Part F386)
DOI: 10.1007/978-3-031-78350-0_15
Böhm J., Breuning C., Markl M., Körner C.:
A new approach of preheating and powder sintering in electron beam powder bed fusion
In: International Journal of Advanced Manufacturing Technology (2024)
ISSN: 0268-3768
DOI: 10.1007/s00170-024-13966-1
Breuning C., Markl M., Körner C.:
Correction to: A Scan Strategy Based Compensation of Cumulative Heating Effects in Electron Beam Powder Bed Fusion (Progress in Additive Manufacturing, (2024), 10.1007/s40964-024-00807-6)
In: Progress in Additive Manufacturing (2024)
ISSN: 2363-9512
DOI: 10.1007/s40964-024-00841-4
Breuning C., Markl M., Körner C.:
A Scan Strategy Based Compensation of Cumulative Heating Effects in Electron Beam Powder Bed Fusion
In: Progress in Additive Manufacturing (2024)
ISSN: 2363-9512
DOI: 10.1007/s40964-024-00807-6
Gaag T., Weidinger J., Bandorf J., Lux V., Wahlmann B., Neumeier S., Zenk C., Körner C.:
Experimental Validation of Property Models and Databases for Computational Superalloy Design
In: Advanced Engineering Materials (2024)
ISSN: 1438-1656
DOI: 10.1002/adem.202401051
Kammermeier E., Weidinger J., Ionov I., Ramsperger M., Wahlmann B., Körner C., Zenk C.:
Accelerating Alloy Development for Additive Manufacturing
15th International Symposium on Superalloys, ISS 2024 (Pennsylvania, PA, 8. September 2024 - 12. September 2024)
In: Jonathan Cormier, Ian Edmonds, Stephane Forsik, Paraskevas Kontis, Corey O’Connell, Timothy Smith, Akane Suzuki, Sammy Tin, Jian Zhang (ed.): Minerals, Metals and Materials Series 2024
DOI: 10.1007/978-3-031-63937-1_11
Koepf JA., Pistor J., Markl M., Körner C.:
Numerical Microstructure Prediction for Lattice Structures Manufactured by Electron Beam Powder Bed Fusion
In: Crystals 14 (2024), Article No.: 149
ISSN: 2073-4352
DOI: 10.3390/cryst14020149
Kupfer T., Breuning C., Markl M.:
Graph-based spot melting sequence for electron beam powder bed fusion
In: Additive Manufacturing 91 (2024), Article No.: 104321
ISSN: 2214-7810
DOI: 10.1016/j.addma.2024.104321
Markl M., Azadi Tinat MR., Berger T., Westrich Y., Renner J., Körner C.:
In-situ electron beam characterization for electron beam powder bed fusion
In: Additive Manufacturing 96 (2024), Article No.: 104567
ISSN: 2214-7810
DOI: 10.1016/j.addma.2024.104567
Markl M., Azadi Tinat MR., Berger T., Renner J., Körner C.:
Extracting powder bed features via electron optical images during electron beam powder bed fusion
In: Additive Manufacturing Letters 10 (2024), Article No.: 100220
ISSN: 2772-3690
DOI: 10.1016/j.addlet.2024.100220
Markl M., Colosimo BM., Körner C.:
Progress in electron beam additive manufacturing
In: Progress in Additive Manufacturing (2024)
ISSN: 2363-9512
DOI: 10.1007/s40964-024-00679-w
Scherr R., Liepold P., Markl M., Körner C.:
A CALPHAD-Informed Enthalpy Method for Multicomponent Alloy Systems with Phase Transitions
In: Modelling 5 (2024), p. 367-391
ISSN: 2673-3951
DOI: 10.3390/modelling5010020
Renner J., Markl M., Körner C.:
In situ build surface topography determination in electron beam powder bed fusion
In: Progress in Additive Manufacturing (2024)
ISSN: 2363-9512
DOI: 10.1007/s40964-024-00621-0
Titz K., Vollhüter J., Randelzhofer P., Neumeier S., Göken M., Wahlmann B., Körner C.:
Design and Characterization of a Novel NiAl–(Cr,Mo) Eutectic Alloy
In: Advanced Engineering Materials (2024)
ISSN: 1438-1656
DOI: 10.1002/adem.202302079
Wahlmann B., Markl M., Körner C.:
A thermo-mechanical model for hot cracking susceptibility in electron beam powder bed fusion of Ni-base superalloys
In: Materials & Design 237 (2024), Article No.: 112528
ISSN: 0264-1275
DOI: 10.1016/j.matdes.2023.112528
Wahlmann B.:
Numerische Entwicklung von Superlegierungen für den Guss und die Additive Fertigung (Dissertation, 2024)
Yang Z., Koepf JA., Markl M., Körner C.:
Effect of scanning strategies on grain structure and texture of additively manufactured lattice struts: A numerical exploration
In: Advanced Engineering Materials (2024)
ISSN: 1438-1656
DOI: 10.1002/adem.202400661
Yang Z., Markl M., Körner C.:
Comprehensive numerical investigation of laser powder bed fusion process conditions for bulk metallic glasses
In: Additive Manufacturing 81 (2024), Article No.: 104026
ISSN: 2214-7810
DOI: 10.1016/j.addma.2024.104026
Yang Z.:
Modeling and Simulation of Bulk Metallic Glass Crystallization During Laser Powder Bed Fusion (Dissertation, 2024)
DOI: 10.25593/open-fau-715
Baumgärtner B., Rothfelder R., Greiner S., Breuning C., Renner J., Schmidt M., Drummer D., Körner C., Markl M., Hausotte T.:
Evaluation of Additively-Manufactured Internal Geometrical Features Using X-ray-Computed Tomography
In: Journal of Manufacturing and Materials Processing (2023)
ISSN: 2504-4494
DOI: 10.3390/jmmp7030095
Breuning C., Böhm J., Markl M., Körner C.:
High-Throughput Numerical Investigation of Process Parameter-Melt Pool Relationships in Electron Beam Powder Bed Fusion
In: Modelling 4 (2023), p. 336-350
ISSN: 2673-3951
DOI: 10.3390/modelling4030019
Breuning C., Markl M., Körner C.:
A return time compensation scheme for complex geometries in electron beam powder bed fusion
In: Additive Manufacturing 76 (2023), p. 103767
ISSN: 2214-7810
DOI: 10.1016/j.addma.2023.103767
Koepf JA., Gotterbarm M., Kumara C., Markl M., Körner C.:
Alternative Approach to Modeling of Nucleation and Remelting in Powder Bed Fusion Additive Manufacturing
In: Advanced Engineering Materials (2023)
ISSN: 1438-1656
DOI: 10.1002/adem.202201682
Mergheim J., Breuning C., Burkhardt C., Hübner D., Köpf J., Herrnböck L., Yang Z., Körner C., Markl M., Steinmann P., Stingl M.:
Additive manufacturing of cellular structures: Multiscale simulation and optimization
In: Journal of Manufacturing Processes 95 (2023), p. 275-290
ISSN: 1526-6125
DOI: 10.1016/j.jmapro.2023.03.071
Nahr F., Rasch M., Burkhardt C., Renner J., Baumgärtner B., Hausotte T., Körner C., Steinmann P., Mergheim J., Schmidt M., Markl M.:
Geometrical Influence on Material Properties for Ti6Al4V Parts in Powder Bed Fusion
In: Journal of Manufacturing and Materials Processing 7 (2023), p. 82
ISSN: 2504-4494
DOI: 10.3390/jmmp7030082
Renner J., Grund J., Markl M., Körner C.:
A Ray Tracing Model for Electron Optical Imaging in Electron Beam Powder Bed Fusion
In: Journal of Manufacturing and Materials Processing 7 (2023), Article No.: 87
ISSN: 2504-4494
DOI: 10.3390/jmmp7030087
Scherr R., Markl M., Körner C.:
Volume of fluid based modeling of thermocapillary flow applied to a free surface lattice Boltzmann method
In: Journal of Computational Physics 492 (2023), Article No.: 112441
ISSN: 0021-9991
DOI: 10.1016/j.jcp.2023.112441
Uddagiri M., Shchyglo O., Steinbach I., Wahlmann B., Körner C.:
Phase-Field Study of the History-Effect of Remelted Microstructures on Nucleation During Additive Manufacturing of Ni-Based Superalloys
In: Metallurgical and Materials Transactions A-Physical Metallurgy and Materials Science (2023)
ISSN: 1073-5623
DOI: 10.1007/s11661-023-07004-0
Wahlmann B., Markl M., Körner C.:
A Thermo-Mechanical Model for Hot Cracking Susceptibility in Electron Beam Powder Bed Fusion of Ni-Base Superalloys
In: Materials & Design 237 (2023), p. 112528
ISSN: 0264-1275
DOI: 10.1016/j.matdes.2023.112528
Yang Z., Huber F., Krapf A., Merle B., Markl M., Schmidt M., Körner C.:
Revealing bulk metallic glass crystallization kinetics during laser powder bed fusion by a combination of experimental and numerical methods
In: Journal of Non-Crystalline Solids 619 (2023), Article No.: 122532
ISSN: 0022-3093
DOI: 10.1016/j.jnoncrysol.2023.122532
Yang Z., Kuesters Y., Logvinov R., Markl M., Körner C.:
SAMPLE3D: A versatile numerical tool for investigating texture and grain structure of materials processed by PBF processes
IVth International Conference on Simulation for Additive Manufacturing (Sim-AM 2023) (München, 26. July 2023 - 28. July 2023)
DOI: 10.23967/c.simam.2023.006
Breuning C., Pistor J., Markl M., Körner C.:
Basic Mechanism of Surface Topography Evolution in Electron Beam Based Additive Manufacturing
In: Materials 15 (2022), Article No.: 4754
ISSN: 1996-1944
DOI: 10.3390/ma15144754
Renner J., Breuning C., Markl M., Körner C.:
Surface topographies from electron optical images in electron beam powder bed fusion for process monitoring and control
In: Additive Manufacturing 60 (2022), Article No.: 103172
ISSN: 2214-7810
DOI: 10.1016/j.addma.2022.103172
Yang Z., Markl M., Körner C.:
Predictive simulation of bulk metallic glass crystallization during laser powder bed fusion
In: Additive Manufacturing 59 (2022), Article No.: 103121
ISSN: 2214-7810
DOI: 10.1016/j.addma.2022.103121
Yang Z., Wang H., Krauß S., Huber F., Merle B., Schmidt M., Markl M., Körner C.:
Evolution of an industrial-grade Zr-based bulk metallic glass during multiple laser beam melting
In: Journal of Non-Crystalline Solids 589 (2022), Article No.: 121649
ISSN: 0022-3093
DOI: 10.1016/j.jnoncrysol.2022.121649
Wahlmann B., Bandorf J., Volz N., Förner A., Pröbstle J., Multerer K., Göken M., Markl M., Neumeier S., Körner C.:
Numerical Design of CoNi-Base Superalloys With Improved Casting Structure
In: Metallurgical and Materials Transactions A-Physical Metallurgy and Materials Science (2022)
ISSN: 1073-5623
DOI: 10.1007/s11661-022-06870-4
Breuning C., Arnold C., Markl M., Körner C.:
A multivariate meltpool stability criterion for fabrication of complex geometries in electron beam powder bed fusion
In: Additive Manufacturing 45 (2021), Article No.: 102051
ISSN: 2214-7810
DOI: 10.1016/j.addma.2021.102051
Kergaßner A., Köpf J., Markl M., Körner C., Mergheim J., Steinmann P.:
A Novel Approach to Predict the Process-Induced Mechanical Behavior of Additively Manufactured Materials
In: Journal of Materials Engineering and Performance (2021)
ISSN: 1059-9495
DOI: 10.1007/s11665-021-05725-0
Küng V., Scherr R., Markl M., Körner C.:
Multi-material model for the simulation of powder bed fusion additive manufacturing
In: Computational Materials Science 194 (2021)
ISSN: 0927-0256
DOI: 10.1016/j.commatsci.2021.110415
Rausch A., Pistor J., Breuning C., Markl M., Körner C.:
New grain formation mechanisms during powder bed fusion
In: Materials 14 (2021), Article No.: 3324
ISSN: 1996-1944
DOI: 10.3390/ma14123324
Wahlmann B., Leidel D., Markl M., Körner C.:
Numerical Alloy Development for Additive Manufacturing towards Reduced Cracking Susceptibility
In: Crystals 11 (2021)
ISSN: 2073-4352
DOI: 10.3390/cryst11080902
Wimler D., Käsznar K., Musi M., Breuning C., Markl M., Keckes J., Clemens H., Körner C., Mayer S.:
How electron beam melting tailors the Al-sensitive microstructure and mechanical response of a novel process-adapted γ-TiAl based alloy
In: Materials & Design 212 (2021), Article No.: 110187
ISSN: 0264-1275
DOI: 10.1016/j.matdes.2021.110187
Yang Z., Bauereiß A., Markl M., Körner C.:
Modeling laser beam absorption of metal alloys at high temperatures for selective laser melting
In: Advanced Engineering Materials 23 (2021), Article No.: 2100137
ISSN: 1438-1656
DOI: 10.1002/adem.202100137
Yang Z., Al-Mukadam R., Stolpe M., Markl M., Deubener J., Körner C.:
Isothermal crystallization kinetics of an industrial-grade Zr-based bulk metallic glass
In: Journal of Non-Crystalline Solids 573 (2021), Article No.: 121145
ISSN: 0022-3093
DOI: 10.1016/j.jnoncrysol.2021.121145

Term: 1. November 2021 - 31. October 2027
Funding source: ERC Advanced Grant
Acronym: AMELI
Project leader: Carolin Körner

Prof. Dr.-Ing. habil. Carolin Körner

Head

Email: carolin.koerner@fau.de

Additive manufacturing (AM), a bottom-up approach that ‘adds’ successive layers to produce a component, has reduced the cost, time and materials’ waste of aerospace parts production while enhancing the design space and properties. Powder bed fusion-electron beam (PBF-EB) AM begins with metal powders that are melted to form the layers. The challenge is to control the AM process to ensure the desired local materials properties. The EU-funded AMELI project will integrate PBF-EB AM with powerful sca…

Modelling and Simulation

Fields of Activity

Team

Publications

Projects

AMELI: Voxel Based Material Design: Amalgamation of Additive Manufacturing and Scanning Electron Microscopy

Contact

AMTrieb: Numerical process optimization for additively tailored microstructures

Contact

SFB/TRR 103 (C07): Multi-criteria calculation of optimum compositions for single crystal superalloys

Contact

Social Media and Websites

SAPHIR: Simulation methods for additive processing of high temperature alloys - microstructure, in-service properties and repair

Contact

SFB 814 (C5): Mesoscopic modelling and simulation of properties of additively manufactured metallic parts (C5)

Contact

SFB 814 (T2): Numerical modeling of local material properties and thereof derived process strategies for powder bed based additive manufacturing of bulk metallic glasses (T2)

Contact

Contact

Social Media and Websites

Modeling and simulation of multi-material processing of metallic materials in beam-based additive manufacturing in the powder bed

Contact

Fundamental mechanisms and modeling of microstructure evolution during beam and powder bed-based additive manufacturing

Contact

Social Media and Websites

SFB 814 (B04): Mesoscopic simulation of the selective beam melting process

Contact

AMAZE: Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products

Contact

FastEBM: High Productivity Electron Beam Melting Additive Manufacturing Development for the Part Production Systems Market

Contact

SIMCHAIN: Development of physically based simulation chain for microstructure evolution and resulting mechanical properties focused on additive manufacturing processes

Contact

Lattice Boltzmann method with free surfaces for viscoelastic materials and their application for the simulation of foam formation

Contact

FreeWiHR: FreeWiHR - Simulation von Metallschäumen

Contact

Lattice Boltzmann method for the simulation of solidification phenomena in the production of foamed materials

Contact