Digital materials design by thermal-fluid science for multi-metal additive manufacturing

Metal additive manufacturing is promising for designing advanced metallic parts of complex geometries. The challenge lies in process control on melt flow dynamics, alloy mixing and vapour mass loss, which significantly vital the final quality. A high-fidelity thermal-solutal-fluid modelling approach including accurate tracking surface shape, thermo-capillary dynamics vaporisation has been developed. Multi-species formulations are also included multi-metal simulation. Using this method, physical link between metal loss 21 transition metals 3 binary alloys investigated. rate governed by a fluid dynamic parameter Reynolds number with simple proportional correlation linked thermal-fluid behavior pool, convective further complicates behaviour in-situ alloying. digital materials effective understanding interdependent can advance process-based design.