Modeling of common defects in additive manufacturing by Tarasankar DebRoy

00:00 Introduction
02:15 Common defects
04:47 Selection of models
05:45 Lack of fusion defects
15:28 Solidification cracking
18:16 Residual stress
20:58 Main contributions

Properties and serviceability of metallic parts made by additive manufacturing are affected by various defects such as cracking, porosity, and other voids, surface roughness, and waviness, loss of alloying elements, residual stress, distortion, and delamination. Their prevention requires optimization of the manufacturing process, alloys, and a large number of process variables. The wide range of variables and the high cost of feedstock and machines make the traditional trial-and-error optimization of process variables to avoid defects expensive and time-consuming. Emerging digital tools of mechanistic modeling and machine learning provide a better understanding of the prevention of common defects in additively manufactured metallic materials. This presentation aims to provide several important examples of the application of these tools to reduce defects and achieve improved quality consistency and cost competitiveness.