Simulation-based process strategies


Powder bed fusion using an electron beam enables the fabrication of highly complex components. The resulting part properties are strongly influenced by the selected process and exposure strategy. Conventional line-based approaches can lead to inhomogeneous temperature histories within individual layers, resulting in spatially varying material properties.

Modern process strategies combine line- and point-based exposure approaches and enable targeted spatial and temporal control of the energy input. By carefully designing preheating, intermediate heating, and melting steps, temperature histories can be actively controlled and homogenized across the entire layer. The development of these strategies is supported by multiscale simulation tools that account for thermal processes, melt pool dynamics, and the resulting microstructural evolution, thereby enabling a sound evaluation of process parameters.

The benefits of these holistic process strategies include improved part quality, reduced defect formation, and more efficient use of energy and processing time. Owing to their systematic design, the concepts are transferable to different geometries and grid structures and form a key foundation for the further development of robust and high-performance strategies in additive manufacturing.


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