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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Algorithms Development in Materials Science and Engineering
Presentation Title A Comparative Study on Finite Volume and Analytical Methods for Melt Pool Predictions in Laser Powder Bed Fusion Process
Author(s) Akshatha C. Dixith, Anthony G. Spangenberger, John Coleman, Diana A. Lados
On-Site Speaker (Planned) Akshatha C. Dixith
Abstract Scope Computational models are useful for reducing the process parameter search space in optimization of additive manufacturing (AM), provided that they efficiently and accurately describe operative physics and are properly calibrated. Thermal history modeling is the first step in such models, and AdditiveFOAM is a well-established platform with a unique two-parameter volumetric heat source capable of simulating both keyhole and conduction mode melt pools. This study conducts model calibration for Ti-6Al-4V and Al-10Si-Mg produced by laser powder bed fusion and validates outcomes with experimental builds with varied laser power and scan speed spanning the process map. Optimal volumetric heat source parameters are obtained using a surrogate model that replaces the high-fidelity physical simulations. The calibrated model is compared with a simpler analytical model and experimental single-track melt pool dimensions to discuss tradeoffs in simulation speed/accuracy and validation of the model.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Computational Materials Science & Engineering, ICME

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