About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
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| Symposium
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Additive Manufacturing: Advanced Characterization With Synchrotron, Neutron, and In Situ Laboratory-scale Techniques IV
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| Presentation Title |
Hybrid CFD–Acoustic Modeling of Acoustic Emissions in Laser Powder Bed Fusion of AlSi10Mg |
| Author(s) |
Ian C. Bacon, Christopher Kube, Lovejoy Mutswatiwa, Tao Sun, Samuel Clark, Allison Beese, Andrea Argüelles, Olivia Van Fleet, Sihang Feng |
| On-Site Speaker (Planned) |
Ian C. Bacon |
| Abstract Scope |
This work presents a hybrid modeling framework for simulating acoustic emissions during laser-based powder bed fusion (LBPF) of AlSi10Mg. Computational fluid dynamics (CFD) software simulates melt pool dynamics replicating LBPF tests conducted at the Advanced Photon Source (APS 32-ID), where high-speed X-ray imaging provides ground truth for melt pool and keyhole geometry. Surface velocities from melt pool and keyhole surfaces are extracted and used as initial conditions in a time-domain acoustic wave propagation model. This enables realistic simulation of both passive and actively excited acoustic signals produced in the argon-filled build chamber. Simulated results are compared with APS measurements, showing strong correlation between modeled and observed acoustic features during keyhole instabilities and pore formation. This framework facilitates digital twin-based optimization of acoustic sensing and supports neural network training using both simulated and experimental data. |
| Proceedings Inclusion? |
Planned: |