Application of fluid dynamics methods in additive manufacturing

With the rapid development of additive manufacturing (AM) technology, the application of fluid mechanics in this field has become increasingly important, as it can help deeply understand the process principle, improve the process parameters, and modify the device structures. The application of fluid mechanics methods in additive manufacturing processes is summarized according to different AM technology types. The different fluid dynamics methods can be used to simulate and investigate the flow process. The main methods or software include ANSYS Fluent, COMSOL, ANSYS CFX, OpenFOAM, and FLOW-3D. In the material extrusion process, by simulating the flow behavior of the material, the rate, stability, and temperature changes of the material during the extrusion process can be studied. In the powder bed melting process, fluid dynamics methods can help simulate the flow behavior of powder inside the powder bed, simulate the temperature distribution inside the powder bed, and predict the shape and size of the molten pool. In direct energy deposition processes, fluid dynamics simulation can be used to study the melting and solidification behavior of materials, as well as the temperature distribution within them, and to simulate the flow behavior of the molten pool, understanding the mixing and distribution of materials, etc. Fluid dynamics simulation can provide an in-depth understanding of fluid flow behavior in additive manufacturing processes and guide process optimization, material design, and component performance.