Multiphysics modelling of high energy density advanced manufacturing processes

The evolution of metallic substrates during arc-based AM processes is governed by the strongly coupled non-linear heat, mass and electromagnetic transport phenomena.

While current approaches to predict the magneto-thermo-hydrodynamic (MTHD) behaviour of such system are limited to single phases with weak electromagnetic property contrast, in AM processes, the electrical conductivity and magnetic permeability can vary by several orders of magnitude between the metallic and atmospheric phases.

An accurate prediction of MTHD in AM requires a mathematical and numerical framework that accounts for multiple phases with large property contrast, descriptions of turbulence development in the fluid region, and solidification.

Such a framework would provide unprecedented fidelity and have widespread industrial impact; particularly in safety critical applications such as the fabrication of primary circuit components in nuclear fission and fusion power plants.