A finite volume–based thermo-fluid-mechanical model of the LPBF process

The multi-physics coupling feature of the laser powder bed fusion (LPBF) process poses great challenges to numerical models regarding computational fidelity and efficiency. This paper proposed a finite volume–based model for predicting integrated thermo-fluid-mechanical behaviors of the LPBF process. The model directly unifies the heat transfer, fluid flow and solid mechanics simulations within a predefined mesh, enabling simultaneous solutions for the fluid domain under Eulerian description and the solid domain under Lagrangian description. Three benchmark tests accounting for individual problems were conducted to validate the model's accuracy and effectiveness. Track-scale LPBF simulations were performed to unravel the intricate interplay between thermal, fluid and mechanical behaviors. The numerical predictions of surface morphologies, molten pool dynamics and melt track dimensions aligned well with the experimental observations. The spatiotemporal evolution of transient thermal stress was accurately captured and the predicted residual stress field showed consistency with nanoindentation measurements. The proposed model was found robust in simultaneously predicting the temperature distribution, melt flow and residual stress evolutions of the LPBF process, and showed strong potential for addressing other similar multi-physics coupling problems.