Powder bed fusion (PBF) process is expeditely moving towards its maturity for the direct manufacturing of intricated and sophisticated metallic parts. The typical process is instead complex and yet challenging to interpret experimentally. Modeling and simulation strategy has been widely implemented to comprehend and optimize the process. Therefore, an integrated simulation approach incorporating stochastic powder deposition and subsequently selective melting is developed to understand the consolidation mechanism in a multilayer process of electron beam PBF additive manufacturing. Simulation results of a thin-walled cross section are validated with the published experimental data to demonstrate the effectiveness of the proposed model. The simulation results of the multilayer process revealed that the layer thickness keeps on slight changes until reaching a steady state during the multilayer additive process. The stable powder layer thickness is systematically analyzed, which proved that the influence of the wall effect should be considered in smaller nominal layer thickness and denser powder bed. Finally, the printing quality in the multilayer process is dependent on adequate inter- and intra-layer bonding when the layer thickness reaches its maximum value, where agglomeration and balling effect in melt pool dynamics predominant by surface tension play crucial roles.

粉末床熔合（PBF）工艺正迅速走向成熟，可直接制造复杂而复杂的金属零件。相反，典型的过程很复杂，但要通过实验进行解释具有挑战性。建模和仿真策略已被广泛实施以理解和优化过程。因此，开发了一种结合了随机粉末沉积和随后的选择性熔化的集成模拟方法，以了解电子束PBF增材制造的多层工艺中的固结机理。薄壁截面的仿真结果已通过已发布的实验数据进行了验证，以证明所提出模型的有效性。多层过程的仿真结果表明，在多层添加过程中，层厚度一直保持微小变化，直到达到稳定状态。系统分析了稳定的粉层厚度，证明在较小的标称层厚度和较密的粉床中应考虑壁效应的影响。最后，当层厚度达到最大值时，多层工艺中的印刷质量取决于层间和层内的适当粘合，其中，以表面张力为主的熔池动力学中的附聚和球化作用起着至关重要的作用。证明了在较小的标称层厚度和较密的粉末床中应考虑壁效应的影响。最后，当层厚度达到最大值时，多层工艺中的印刷质量取决于层间和层内的适当粘合，其中，以表面张力为主的熔池动力学中的附聚和球化作用起着至关重要的作用。这证明了在较小的标称层厚度和较密的粉末床中应考虑壁效应的影响。最后，当层厚度达到最大值时，多层工艺中的印刷质量取决于层间和层内的适当粘合，其中，以表面张力为主的熔池动力学中的附聚和球化作用起着至关重要的作用。