Space-time hp finite elements for heat evolution in laser-based additive manufacturing

TL;DR

This paper introduces a space-time finite element method for simulating heat evolution in laser-based additive manufacturing, enabling efficient large-scale parallel computations and improved multi-scale modeling.

Contribution

It develops a four-dimensional, locally refined mesh framework with variable temporal accuracy, enhancing scalability and accuracy over classical time-stepping methods.

Findings

Accurately reproduces melt pool shape in benchmark tests.

Demonstrates potential for large-scale parallel simulations.

Achieves significant computational efficiency improvements.

Abstract

The direct numerical simulation of metal additive manufacturing processes such as laser powder bed fusion is challenging due to the vast differences in spatial and temporal scales. Classical approaches based on locally refined finite elements combined with time-stepping schemes can only address the spatial multi-scale nature and provide only limited scaling potential for massively parallel computations. We address these shortcomings in a space-time Galerkin framework where the finite element interpolation also includes the temporal direction. In this setting, we construct four-dimensional meshes that are locally refined towards the laser spot and allow for varying temporal accuracy depending on the position in space. By splitting the mesh into conforming time slabs, we recover a stepwise solution to solve the space-time problem locally in time at this slab; additionally, we can choose time-slab sizes significantly larger than classical time-stepping schemes. As a result, we believe this setting to be well suited for large-scale parallelization. In our work, we use a continuous Galerkin-Petrov formulation of the nonlinear heat equation with an apparent heat capacity model to account for the phase change. We validate our approach by computing the AMB2018-02 benchmark, where we obtain an excellent agreement with the measured melt pool shape. Using the same setup, we demonstrate the performance potential of our approach by hatching a square area with a laser path length of about one meter.