Learning Forum

[Krzysztof Stopka]

Hello all,

I have a question on the topic of the four Additive Science Simulations shown in the screenshot below. I understand that these work towards the final module “Performing a Microstructure Simulation” that would predict regions of potential lack of fusion porosity in a cube (or hopefully, a full component). While reading through “Performing a Single Bead Parametric Simulation”, it was not clear to me whether this is exclusively a simulated exercise, or whether this requires experimental validation in the form of a physical single bead print that is experimentally characterized and compared to the simulated beads. In other words, are the parametric simulations performed in the Additive Science Simulations pre-validated for certain materials of interest (e.g., Ti-6Al-4V, IN625, etc.), or does a user need to perform some other type of experimental validation/calibration to be able to predict lack of fusion porosity? Please let me know if I should elaborate further and thank you in advance.

Best regards,

Krzysztof Stopka

[Akshay Maniyar]

Hi,

The Ansys Additive Science tool is designed to provide detailed guidance on the machine's process parameters and predictions at a microscopic level, which includes the ability to predict the lack of fusion porosity via powder-solid state tracking. For accurate predictions, especially when dealing with new materials or alloys, it is critical to qualify parts for production use, which may suggest that some form of experimental validation or calibration could be necessary to ensure the simulations align with real-world outcomes. Given the complexity of additive manufacturing processes and the potential for unmodeled phenomena, such as latent heat and surface tension effects, which are not accounted for in the simulation, it would be prudent to perform experimental validation to confirm the simulation results.

Thanks,

Akshay Maniyar

[Krzysztof Stopka]

Hi Akshay,

Thank you for your detailed response. I agree that it would be prudent to perform some type of experimental characterization to validate the simulations in Additive Science. However, the simulations themselves are quite involved. Does ANSYS have any guidance as to how these simulations should be experimentally validated such that the most accurate predictions of LOF porosity are provided? For example, is there a guide on performing companion single bead experiments, how these should be characterized, and how to then input this data as parameters for Additive Suite to maximize prediction accuracy? Otherwise, I am unsure how the Additive Suite can be of use for LOF porosity prediction of physical cube specimens or actual components.

Best regards,

Krzysztof Stopka

[John Doyle]

There are references that validate the Additive Science calculations. For instance, the grain shape in Ansys Additive Science is calculated using the circle equivalence method, which is a common technique in material science and EBSD-SEM microscopes. This method calculates the grain size of non-circular or irregular shaped grains by equating the area of each grain to that of a circle and computing the diameter based on this area. For a detailed understanding, you can refer to the Additive Print and Science Users Guide and the paper titled 'Understanding Grain Evolution in Additive Manufacturing Through Modeling' by Akram, Javed, et. al., (2018), which also provides additional reference papers for further study [2]. URL: [2] /forum/forums/topic/ansys-additive-microstructure-simulation-2/

Additionally, the Additive Print and Science User's Guide includes sections on Machine Configuration, Reviewing Results, Microstructure Validation Process, Known Issues and Limitations, and References that can be useful for understanding the validation process for Additive Science calculations [3]. URL: [3] https://ansyshelp.ansys.com/Views/Secured/corp/v232/en/add_print/add_print.html

References:
[1] Title: "Are there any reference papers to validate the sample material properties found in Engineering Data specifically for Additive Manufacturing applications?", URL: /knowledge/forums/topic/are-there-any-reference-papers-to-validate-the-sample-material-properties-found-in-engineering-data-specifically-for-additive-manufacturing-applications/
[2] Title: "Application of Circle Equivalence Method for Grain Size Calculation in Ansys Additive Science: Detailed Study and Reference Materials", URL: /forum/forums/topic/ansys-additive-microstructure-simulation-2/
[3] Title: "Additive Print and Science User's Guide", URL: https://ansyshelp.ansys.com/Views/Secured/corp/v232/en/add_print/add_print.html