Powder bed fusion comprises all layer‐by‐layer additive manufacturing technologies of parts built from a powder bed. To exploit the advantages of near‐net shape manufacturing of complex geometries, in contrast to conventional manufacturing techniques, it is essential to understand the underlying physical phenomena occurring during processing for a broad range of different process scenarios. Experimental approaches are costly in time and material and provide only limited access inside the process. However, to understand the process behavior and predict final properties of parts, numerical approaches are powerful tools. This work presents the software suite S𝔸𝕄PLE (Simulation of Additive Manufacturing on the Powder scale using a Laser or Electron beam) which simulates the consolidation and microstructure evolution during beam‐based powder bed fusion processes. It is based on a mesoscopic approach, in which statistical powder beds, melt pool dynamics, evaporation effects, and microstructure evolution are considered and can simulate the build‐up of more than 100 layers. The underlying models and algorithms of the software including a newly applied thermal model are described. Finally, the unique potential of the software is demonstrated by reviewing the influence of various powder bed properties, the effects of evaporation, and the grain structure evolution in the process.

中文翻译：

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S𝔸𝕄PLE：预测粉末床熔合增材制造固结和微观结构的软件套件

粉末床融合包括由粉末床制造的零件的所有逐层增材制造技术。与传统的制造技术相比，要利用复杂形状的近净形制造的优势，必须了解在各种不同工艺场景的加工过程中发生的潜在物理现象。实验方法在时间和材料上都是昂贵的，并且仅在过程内部提供有限的访问。但是，要了解过程行为并预测零件的最终特性，数值方法是强大的工具。这项工作介绍了软件套件S𝔸𝕄PLE（使用激光或电子束在粉末规模上模拟增材制造），可模拟基于束的粉末床熔融过程中的固结和微观结构演变。它基于介观方法，其中考虑了统计粉末床，熔池动力学，蒸发效应和微观结构演变，并可以模拟100多个层的堆积。描述了软件的基础模型和算法，包括新应用的热模型。最后，通过回顾各种粉末床性能的影响，蒸发的影响以及过程中晶粒结构的演变，证明了该软件的独特潜力。