Multiscale modeling applied to additive manufacturing

Metal additive manufacturing has shown promising applications and great potentials in various industrial sectors. However, wide applications are still hindered by defects and quality inconsistency. Therefore, a comprehensive understanding of complex physics across multiple scales is extremely valuable. Here, we introduce the cutting-edge multiscale modeling approaches used in metal additive manufacturing, spanning from the manufacturing processes to microstructure evolutions and finally to mechanical properties. The multiscale modeling of the manufacturing processes includes the electron/photon-atom interactions at the microscale, powder particle motion and phase transformations at the mesoscale, and thermal stress evolution at the mesoscale and macroscale. The modeling of microstructure evolutions incorporates microscale dendrite growth and mesoscale grain growth. The modeling of the mechanical properties starts from the crystal plasticity model to the representative volume element for the constitutive relationships in the macroscale continuum model. © 2023 Elsevier Inc. All rights reserved.