Utility of superposition-based finite element approach for part-scale thermal simulation in additive manufacturing

The utility of a superposition-based finite element approach is explored for part-scale thermal simulation in additive manufacturing. The approach consists of summing a nearly analytic solution for a moving source in a semi-infinite medium with a correcting finite domain field computed with finite element analysis. The accuracy and computational expense of the approach are tested against a fully converged traditional finite element approach. Through efficient implementation of the nearly analytic solution and the use of a coarse finite element mesh away from surfaces, part-scale thermal modeling appears possible without sacrifices in accuracy, at least in the context of the linear heat equation.