Papers
This page contains the peer-reviewed scientific publications that back up the models and theories implemented in our AM-DT digital twin platform.
Understanding spatial variability in mechanical properties of laser powder-bed fusion parts under material uncertainty
The paper develops a multiscale uncertainty-propagation framework for PBF-L, tracking how uncertain thermal conductivity, heat capacity, and density affect powder-scale and part-scale predictions. It quantifies spatial variability in mechanical properties and shows how build orientation and baseplate contact influence uncertainty. Open paper
Understanding and control of gas porosity in metal laser powder-bed fusion additive manufacturing
This study couples melt-pool fluid dynamics, ray tracing, and phase-field/interface tracking to explain gas-pore formation in LPBF. It identifies low scan speeds and stripe turning points as critical pore sources, then demonstrates how laser power modulation can reduce pore emission. Open paper
Phase field study of heat treatment and strengthening in maraging steels
The abstract presents a phase-field model for martensite decomposition during heat treatment of maraging steels, including precipitate growth, reverted austenite, and transformation-induced deformation. The simulations connect ageing temperature and time to strength trends and clarify the role of reversed austenite. Open paper
The role of tool path on microstructure uniformity in large-format additive manufacturing
The paper introduces an integrated thermo-metallurgical-mechanical model for directed energy deposition that reads the robot toolpath and component geometry directly. It links toolpath choices to temperature, phase distribution, residual stress, and distortion in large-format metal AM. Open paper
Data-driven surrogate modelling of residual stresses in Laser Powder-Bed Fusion
The study evaluates fast surrogate models for LPBF residual-stress prediction using simulation-generated data from two families of part geometries. It compares neural-network and interpolation strategies as practical alternatives to expensive multiphysics simulations for optimization, control, and digital twinning. Open paper
Development of a surrogate model for high-fidelity laser powder-bed fusion using tensor train and Gaussian process regression
The paper proposes a tensor-train and Gaussian-process surrogate for a high-fidelity LPBF powder-scale model. It predicts thermal histories and melt-pool geometry for new laser powers in less than one second, achieving large speedups while preserving useful accuracy. Open paper
Discrete element simulation of powder flow in revolution powder analyser
Using DEM simulations of a revolution powder analyser, the paper studies how powder size distribution, non-sphericity, friction, filling degree, rotation speed, and adhesion affect packing density and avalanche flow. It also extracts intrinsic powder friction and adhesion parameters from measurements. Open paper
A part-scale, feature-based surrogate model for residual stresses in the laser powder bed fusion process
This work trains a 3D U-Net convolutional neural network on feature-based LPBF simulations to predict part-scale residual stress. It demonstrates good accuracy for designed feature families and substantial runtime reduction for practical design-stage stress estimation. Open paper
Concurrent modeling of porosity and microstructure in multilayer 3D simulations of INCONEL 718 powder-bed fusion
The paper presents a coupled phase-field and lattice-Boltzmann framework that explicitly models porosity and grain microstructure across multiple LPBF layers in 3D. After calibration, it predicts porosity and microstructure trends across process-parameter combinations. Open paper
Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion
This paper combines simulations and LPBF experiments to study distortion in thin-wall IN718 structures. It shows that rounded corners reduce distortion, part width is more influential than height, and geometry design can suppress buckling during printing. Open paper
Quantitative study on the dynamics of melt pool and keyhole and their controlling factors in metal laser melting
The paper couples ray tracing, phase field, and lattice-Boltzmann methods to reproduce experimentally observed laser-melting regimes in Ti-6Al-4V. It identifies keyhole and melt-pool oscillation modes and links keyhole-tip instability to bubble spill-over. Open paper
Phase field model for multiphase alloys under arbitrary thermal history: an application to IN718 super-alloy
This work builds a phase-field framework for precipitate evolution under arbitrary thermal histories, parameterized with thermodynamics, kinetics, and TTT data. Applied to IN718, it predicts how rapid AM-like thermal cycling changes gamma prime, gamma double-prime, and delta precipitation. Open paper
Modelling the influence of process parameters on precipitate formation in powder-bed fusion additive manufacturing of IN718
The paper develops a two-scale finite-element and phase-field workflow for IN718 powder-bed fusion. Stripe-resolved thermal histories are passed into phase-field RVEs to predict precipitate formation and show how process parameters such as stripe width and chamber temperature affect as-built microstructure. Open paper