Computational Thermal Multi-phase Flow for Metal Additive Manufacturing

Jinhui Yan, Qiming Zhu, Ze Zhao

Research output: Chapter in Book/Report/Conference proceedingChapter


Thermal multi-phase flow simulations are indispensable to understanding the multi-scale and multi-physics phenomena in metal additive manufacturing (AM) processes, yet accurate and robust predictions remain challenging. This book chapter summarizes the recent method development by Yan, Zhu, and Zhao at University of Illinois Urbana-Champaign Champaign for simulating thermal multi-phase flows in laser powder bed fusion (LPBF) and directed energy deposition (DED) processes. Two main method developments are discussed. The first is a mixed interface-capturing/interface-tracking computational framework aiming to explicitly treat the gas-metal interface without mesh motion/re-meshing. The second is a physics-based and non-empirical deposit geometry model for DED processes. The proposed framework’s accuracy is assessed by thoroughly comparing the simulated results against experimental measurements on various quantities. We also report critical quantities that experiments can not measure to show the predictive capability of the developed methods.

Original languageEnglish (US)
Title of host publicationModeling and Simulation in Science, Engineering and Technology
Number of pages48
StatePublished - 2023
Externally publishedYes

Publication series

NameModeling and Simulation in Science, Engineering and Technology
VolumePart F1665
ISSN (Print)2164-3679
ISSN (Electronic)2164-3725

ASJC Scopus subject areas

  • Modeling and Simulation
  • General Engineering
  • Fluid Flow and Transfer Processes
  • Computational Mathematics


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