Coupling melt-pool fluid dynamics to microstructure development to process-aware material model in the Exascale Additive Manufacturing project

The Exascale Additive Manufacturing (AM) project (ExaAM) is focused on metal AM process modeling at the fidelity of the microstructure. To date, ExaAM has instantiated exascale-ready continuum simulations of the AM build and the re-solidification process from fluid dynamics simulations of the laser scan. The calibrated continuum fluid dynamics simulations are used to drive microstructure development simulations from which properties are calculated. Using the AMBench-01 problem as a test case, we generate an ensemble of microstructures and properties from which a continuum material model is determined. While potentially unique to the AMBench-01 build, this process-aware material model enables build simulations closer to AM conditions and part-scale qualification simulations in as-built material conditions. Comparison will be made to experiments of microstructure, properties and build.