This article proposes a novel high-performance computing approach for the prediction of the temperature field in powder bed fusion (PBF) additive manufacturing processes. In contrast to many existing approaches to part-scale simulations, the underlying computational model consistently resolves physical scan tracks without additional heat source scaling, agglomeration strategies or any other heuristic modeling assumptions. A growing, adaptively refined mesh accurately captures all details of the laser beam motion. Critically, the fine spatial resolution required for resolved scan tracks in combination with the high scan velocities underlying these processes mandates the use of comparatively small time steps to resolve the underlying physics. Explicit time integration schemes are well-suited for this setting, while unconditionally stable implicit time integration schemes are employed for the interlayer cool down phase governed by significantly larger time scales. These two schemes are combined and implemented in an efficient fast operator evaluation framework providing significant performance gains and optimization opportunities. The capabilities of the novel framework are demonstrated through realistic AM examples on the centimeter scale including the first scan-resolved simulation of the entire NIST AM Benchmark cantilever specimen, with a computation time of less than one day. Apart from physical insights gained through these simulation examples, also numerical aspects are thoroughly studied on basis of weak and strong parallel scaling tests. As potential applications, the proposed thermal PBF simulation framework can serve as a basis for microstructure and thermo-mechanical predictions on the part-scale, but also to assess the influence of scan pattern and part geometry on melt pool shape and temperature, which are important indicators for well-known process instabilities.

翻译：本文提出一种新型高性能计算方法，用于预测粉末床熔融（PBF）增材制造过程中的温度场。与现有众多面向部件级模拟的方法不同，本计算模型无需额外的热源缩放、聚集策略或任何其他启发式建模假设，即可持续解析物理扫描轨迹。采用自适应细化的动态网格精确捕捉激光束运动的所有细节。关键之处在于，为解析扫描轨迹所需的精细空间分辨率，结合此类过程固有的高扫描速度，必须采用较小的时间步长以解析底层物理过程。显式时间积分方案适用于这一场景，而针对由显著更大时间尺度控制层间冷却阶段，则采用无条件稳定的隐式时间积分方案。两者结合并嵌入高效快速算子评估框架中，显著提升性能并创造优化空间。通过厘米级真实增材制造实例（包括首次完成整个NIST AM基准悬臂梁试样扫描解析模拟，计算时间少于一天）验证了新框架的能力。除通过模拟实例获得的物理洞察外，还基于弱扩展与强扩展并行测试深入研究了数值特性。作为潜在应用，该热PBF模拟框架既可服务于部件级微观结构与热-力学预测，也可评估扫描路径与部件几何形状对熔池形态及温度的影响——这些均为已知工艺不稳定性的重要表征指标。