Aufbau eines numerischen Modells zur Single-Bead-Parametrisierung im SLM-Prozess für CuCr1Zr

This master¿s thesis aims to develop a numerical model that describes the melting process in laser powder bed fusion. The objective of this development is to parameterise the melt pool geometry of individual tracks. Due to the high thermal conductivity and reflectivity of copper alloys, reliable processing in SLM poses a particular challenge. To overcome this, an in-depth understanding of the underlying physical mechanisms is required. Firstly, the theoretical fundamentals of the SLM process, as well as relevant physical and mathematical models, are described. Subsequently, a numerical model based on the finite element method is developed using Abaqus AM-Modler. This model is used to simulate the transient thermal processes that occur during laser irradiation. Particular attention is paid to the modelling of heat input, material properties, and the discretisation and solution of the underlying system of equations. In parallel with the simulation, experimental investigations are being carried out in which samples made of CuCr1Zr are produced and subjected to metallographic analysis. The evaluation of the molten pool geometry forms the basis for comparing the experimental results with the numerical predictions. The results show that the developed model is capable of qualitatively representing the characteristic properties of the molten baths. Furthermore, it is possible to illustrate relationships between process parameters and molten bath geometry. This work thus contributes to a better understanding of the SLM process for copper alloys and provides a basis for the targeted optimisation of process parameters.