Modelling and simulation are very important for revealing the relationship between process parameters and internal variables like grain morphology in solidification, precipitate evolution, and solid-state phase transformation in laser additive manufacturing. The impact of the microstructural changes on mechanical behaviors is also a hot topic in laser additive manufacturing. Here we reviewed key developments in thermal modelling, microstructural simulations, and the predictions of mechanical properties in laser additive manufacturing. A volumetric heat source model, including the Gaussian and double ellipsoid heat sources, is introduced. The main methods used in the simulation of microstructures, including Monte Carlo method, cellular automaton, and phase field method, are mainly described. The impacts of the microstructures on mechanical properties are revealed by the physics-based models including a precipitate evolution based model and dislocation evolution based model and by the crystal plasticity model. The key issues in the modelling and simulation of laser additive manufacturing are addressed.

A new method of controlling the residual stress in laser directed energy deposition additive manufacturing (DED AM) products proposed based on constraints used in manufacturing and the substrate design. The simulation results of the residual stress, which were validated with the experimental measured data, showed that weaker constraints on the substrate could greatly decrease the residual stress in the laser DED AM products. In addition, by designing local reduced thickness regions into the substrate, such as long strip holes or support legs, the residual stress in DED AM products could be further decreased. In this study, when long strip holes were designed in the substrate, the tensile residual stress was decreased by 28%. An even smaller amount of residual stress was achieved when the design structure was changed to support legs. The tensile residual stress decreased by more than 30%. The fewer support legs, the smaller the residual stress. The residual stress in DED AM products could be well-controlled by design, while the stiffness can be weakened with fewer constraints.

In this study, the substrate design-based method of controlling the residual distortion in directed energy deposition additive manufacturing (DED AM) is proposed, in which the stiffness weakened interval is formed by designing long strip holes in the substrate. The effects of the designed substrates are studied using the sequentially coupled thermal-mechanical model. It is found that by rapidly releasing the thermal distortion through the designed stiffness-weakened substrate, the residual distortion of the DED AM product can be decreased by more than 60%. In the design of the stiffness weakened interval, a definition of the configuration ratio is adopted to study the design parameters of the long strip holes on the release of the thermal distortion. When the length coefficient and the spacing coefficient is designed between 0.25 and 0.35 and lower than 0.2, respectively, the residual distortion of the DED AM as-built sample can be decreased by 75%-85% without the extra distortion caused by the excessive decrease of the stiffness of the substrate. The simulated results were indirectly verified by the experimental data. This paper provides a new controlling method of the residual distortion in the laser DED AM product by designing the stiffness-weakened substrate.

In the present study, a thermal–electromagnetic hydrodynamics model has been used to study welding temperature and melt flow characteristics during the laser welding of 316L steel. This welding was performed using an assisted electromagnetic field. In addition, a Monte Carlo model was used to study grain growth during solidification with the purpose of achieving a better understanding of the control of the microstructure. Based on the numerical model, which has been validated by experimental data, the effects of the current intensity of the electromagnetic field on the temperature distribution, melt flow characteristics, and grain growth are discussed here in detail. The simulation results showed that both Marangoni convection and welding temperature could be controlled by the magnetic damping effect, and that they increased due to the electromagnetic heating effect when using an electromagnetic field. Furthermore, when controlling the temperature distribution and melt flow velocity in the laminar flow of the melt pool, which was assisted by a 30 A current intensity of the electromagnetic field, the temperature gradient decreased by 13.5%. This decrease could be even larger than 50% when a turbulent flow was formed in the melt pool, which has here been demonstrated for a current intensity of 100 A. In addition, undercooling was found to decrease because of the increase in the melt flow velocity when using an assistive electromagnetic field. This led to a longer nucleation time in the melt pool. Furthermore, more and larger directional columnar grains, grown by the driving force of the temperature gradient, could be formed after the consumption of the small, nucleated grains near the solid–liquid interface. In short, by controlling the temperature distribution and melt flow velocity, the required grain morphology (equiaxed or columnar) and dimension (radius, length, or width) can be controlled by coarsening and epitaxial growth.