Multiscale modelling techiniques were used to model the process chain for manufacturing gamma titanium aluminde components. The system integrates the different process models at a number of different scales. The modellig work includes:

  • CFD simulations of the powder feed and powder distribution
  • Phase field models for studying material diffusion, interface formation and mechanical properties
  • Micro-mechanical modelling of typical microstructures
  • Continuum cohesive zone modelling, representative volume element modelling and submodelling of materials subjected to thermomechanical loading via laser heating and mechanical cutting.

The multiscale model allows the microstructure of the additive parts to be optimised and predicts areas of high stress in the proposed build. The models were validated against built samples and correcty predicted the bead width and height along and areas where cracking was seen.

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