Metal particle fusion analysis for additive manufacturing using the stabilized optimal transportation meshfree method

A continuum framework for the finite deformation phase change problem is developed. For its numerical solution the stabilized Optimal Transportation Meshfree Method (OTM) is employed. The advantage of meshfree over conventional mesh based techniques is that the treatment of particle fusion is intrinsic to the formulation. This is important to resolve the complex moving boundaries between liquid melt flow and solid metal. In a numerical example consisting of two metal powder particles, the influence of laser heating and cooling conditions on melting and consolidation is analyzed. A detailed parameter study is presented. The insight gained from the simulations may help to narrow the parameter window for further investigations.