Solidification in metal additive manufacturing: challenges, solutions, and opportunities

S Chandra, J Radhakrishnan, S Huang, S Wei… - Progress in materials …, 2024 - Elsevier
The physics of alloy solidification during additive manufacturing (AM) in methods such as
laser powder bed fusion (LPBF), electron beam powder bed fusion (EPBF), and laser …

A comprehensive review of recent advances in laser powder bed fusion characteristics modeling: metallurgical and defects

SF Nabavi, H Dalir, A Farshidianfar - The International Journal of …, 2024 - Springer
This comprehensive review explores recent advancements in laser powder bed fusion
(LPBF) modeling, with a particular focus on metallurgical, temperature, and defect aspects …

Accelerating phase-field simulation of three-dimensional microstructure evolution in laser powder bed fusion with composable machine learning predictions

JY Choi, T Xue, S Liao, J Cao - Additive Manufacturing, 2024 - Elsevier
Phase-field (PF) modeling is a versatile physics-based computational method that has been
used to simulate the evolution of microstructures. The PF method can produce accurate …

[HTML][HTML] Influence of recoil pressure, mushy zone flow resistance and reflectivity on melt pool shape in laser powder bed fusion simulation

J Katagiri, M Kusano, S Nomoto, M Watanabe - Case Studies in Thermal …, 2023 - Elsevier
Melt pool dimensions (depth: D and width: W) are strongly correlated with defects generated
in laser powder bed fusion. The melt pool dimensions have been evaluated by CFD …

[HTML][HTML] On microstructure development during laser melting and resolidification: An experimentally validated simulation study

AF Chadwick, JGS Macías, A Samaei, GJ Wagner… - Acta Materialia, 2025 - Elsevier
Integrating experiment and simulation provides invaluable insights into the critical
parameters that determine the microstructure of alloys produced by additive manufacturing …

A hybrid Potts Monte Carlo model with realistic time scaling to simulate prior austenite structures in additively manufactured high-strength steel

S Cluff, C Mock, A Villegas - Additive Manufacturing, 2025 - Elsevier
Computationally efficient models are required to understand the relationship between
additive manufacturing (AM) processes, such as directed energy deposition (DED), and the …

Grain structure and texture selection regimes in metal powder bed fusion

M Rolchigo, J Coleman, GL Knapp, A Plotkowski - Additive Manufacturing, 2024 - Elsevier
Additive manufacturing (AM) offers opportunities to produce complex part geometries not
possible with conventional processing and in some cases even improve part performance …

A multiscale model for efficiently simulating laser powder bed fusion process with detailed microstructure and mechanical performance results

Y Chen, Y Wang, Y Lu, B Han, K Huang, X Fang… - Materials Science and …, 2024 - Elsevier
Numerical simulation is regarded as an important method for studying the mechanisms of
additive manufacturing (AM), especially in building a multiscale simulation model. However …

Investigation of heat transfer, dendrite growth, Nb segregation, competitive growth, and remelting process during wire-arc directed energy deposition of IN718 using a …

L Wang, J Ding, X Zhang, K Zhang, H Li, W Ou… - International Journal of …, 2025 - Elsevier
In this work, a multi-scale, multi-dimension and multi-area phase field model is established
to simulate the heat transfer, dendrite growth, Nb segregation, competitive growth, and …

Multi-layer multi-track molten pool flow and grain morphology evolution of Inconel 718 manufactured by laser powder bed fusion

H Lu, X Hu, J Pan, Z An, Y Gu - The International Journal of Advanced …, 2024 - Springer
The selective orientation of grains during laser powder bed fusion (L-PBF) leads to
anisotropy in mechanical properties. The current understanding of the evolution between the …