基于粉末级成型模拟的金属增材制造工艺优化

The problem of pore defects in metal additive manufacturing has a large impact on the performance of manufactured components, and how to set the process parameters to reduce such defects is a key challenge in metal additive manufacturing. In this paper, optimal transportation meshfree (OTM) method combined with powder scale model was used to directly simulate the strong fluid-solid-thermal coupling process in the coaxial powder feeding process, and to predict the pore distribution and morphology of the results, and the accuracy was verified by comparing with the experimental results. On this basis, the influence law of process parameters-porosity was established based on the data-driven idea, and the optimal process parameters in the design space were obtained by combining with Multi-Island Genetic Algorithm (MIGA). The results show that the simulation results using the optimised process parameters have a complete shape and significantly reduced porosity, which are consistent with the experimental porosity, width and height measurements, indicating that the combination of powder-level direct numerical simulation technology and the optimal design method is a feasible strategy to achieve the optimisation of the process parameters for metal additive manufacturing.