Simufact Additive: PBF process and defect analysis

Predicting Defects in Full-Scale Geometries

This module incorporates a cutting-edge multi-scale, hybrid analytical-numerical model-based process simulation approach. Developed in collaboration with Pratt & Whitney (P&W) and the Raytheon Technologies Research Center (RTRC), this breakthrough technology is now an integral part of Simufact Additive software by Hexagon Manufacturing Intelligence, Inc. (Hexagon).

This advanced model empowers engineers with the ability to predict thermal history and defects at both the individual scan vector and powder layer levels within minutes. It goes beyond conventional simulations by accurately forecasting the risk of local defects, including keyholing, lack of fusion, balling up, and surface roughness.

Identify ideal process parameters

Single stripe maps and singe track maps allow users to identify the defect-free range of laser power and scan speed for the corresponding process settings and material defined for the machine.

The model is able to predict risk of local defects including keyholing, lack of fusion, balling up, and surface roughness.Further it can determine the process parameter window locally for any location within the part, based on the local geometry and temperature of the substrate before the laser is applied locally, which is calculated by a combined analytical-numerical approach on the part scale and also depends on material properties, operational conditions, and part geometry.

2D and 3D Results

Defect and post-exposure stripe temperature maps are layer based 2D results which display possible defects per layer during a PBF process.

The defect maps shows the defect and defect free regions in a part layer i.e. keyhole porosity, unmelt etc. while the post-exposure stripe temperature shows the stripe temperature after laser exposure per layer during build. It visually represents the stripes produced by the laser.

In addition to that, roughness map and temperature are surface results which represents the surface roughness and final temperature of the part in 3D at the end of the PBF process.