The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.
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December 2015
Research Article|
December 29 2015
Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges
W. E. King
;
W. E. King
a)
1Physical and Life Sciences Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
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A. T. Anderson;
A. T. Anderson
2Engineering Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
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R. M. Ferencz;
R. M. Ferencz
2Engineering Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
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N. E. Hodge;
N. E. Hodge
2Engineering Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
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C. Kamath;
C. Kamath
3Computation Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
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S. A. Khairallah;
S. A. Khairallah
2Engineering Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
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A. M. Rubenchik
A. M. Rubenchik
4NIF and Photon Sciences Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
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W. E. King
1,a)
A. T. Anderson
2
R. M. Ferencz
2
N. E. Hodge
2
C. Kamath
3
S. A. Khairallah
2
A. M. Rubenchik
4
1Physical and Life Sciences Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
2Engineering Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
3Computation Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
4NIF and Photon Sciences Directorate,
Lawrence Livermore National Laboratory
, Livermore, California 94550, USA
a)
Author to whom correspondence should be addressed. Electronic mail: [email protected]
Appl. Phys. Rev. 2, 041304 (2015)
Article history
Received:
September 08 2015
Accepted:
November 03 2015
Citation
W. E. King, A. T. Anderson, R. M. Ferencz, N. E. Hodge, C. Kamath, S. A. Khairallah, A. M. Rubenchik; Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges. Appl. Phys. Rev. 1 December 2015; 2 (4): 041304. https://doi.org/10.1063/1.4937809
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