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Add updates to melt pool with mass addition for DED demonstration with temperature dependent properties #127

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nuneinl opened this issue Apr 26, 2024 · 0 comments
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nuneinl commented Apr 26, 2024

Reason

Update to current and additional level-set and thermal materials to be temperature dependent including modification to powder addition, melt pool heat sources, and momentum sources, for use in example and calibration problems of laser blown powder directed energy deposition (DED). Demonstration is done with 316L stainless steel and Inconel 718 materials for 2D cross-sectional clad geometry.

Design

  1. Deposition Location is calculated in a function material and parsed to laser heat source and powder addition, where they can be coaxial or have separate locations by using two materials. This makes calculation of heat source and mass addition occur separate from location making for future updates with complex toolpaths (CSV) easier to implement.
  2. Deposition location can also take a post processor which can use find the current location of the level-set interface allowing for better representation of heat source interaction at the interface. The current location of the level-set interface can be found with a generic post processor FindValueOnFunctionLine. Where a variable value can be returned at the function location in time and space.
  3. The melt pool heat source has been moved to a material and vaporization heat source is separated to its own material where it is only included in the melt pool heat source if defined. Laser efficiency and gaussian shape are included and this heat source is used in conjunction with ADMatHeatSource
  4. Powder addition also uses the Deposition Location and implements powder efficiency and a temperature dependence based on liquid fraction to only capture mass one melting has occurred.
  5. Melt pool momentum material is modified to include an optional Boussinesq force.
  6. Function temperature dependent properties are defined for below the solidus temperature and above the liquidus temperature calculated in the mushy zone.
  7. Demonstration and examples to include full documentation to be used in the MALAMUTE theory manual.
  8. Examples will have a user friendly input deck which allows easy access to process parameters and conditions through well explained comments and global variables.

Impact

Enhancement will add new features more representative of the physical phenomena in the melt pool and versatility for various types of DED problems. Demonstration and examples will mirror the model used an upcoming MALAMUTE publication with experimental validation of DED single-track clads for 316L and Inconel 718.

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