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Co-authored-by: Kincaid, Kellis <kincaidkc@ornl.gov> Co-authored-by: Knapp, Gerry <knappgl@ornl.gov>
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# Editor and misc backup files - anywhere | ||
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@software{john_coleman_2023_doi, | ||
author = {John Coleman}, | ||
title = {AdditiveFOAM}, | ||
version = {0.0}, | ||
date = {June 2023}, | ||
publisher = {Zenodo}, | ||
url = {}, | ||
doi = {} | ||
} |
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# AdditiveFOAM | ||
AdditiveFOAM is a free, open source heat and mass transfer software for simulations of Additive Manufacturing (AM) released by Oak Ridge National Laboratory. It is built upon OpenFOAM, a free, open source computational fluid dynamics (CFD) software package released by the OpenFOAM Foundation. | ||
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## Citing | ||
If you use AdditiveFoam in your work, please cite the [source code](CITATION.bib). Also, please consider citing relevant AdditiveFOAM **Publications** listed below. | ||
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## Contributors | ||
- [John Coleman](https://www.ornl.gov/staff-profile/john-s-coleman) | ||
- [Kellis Kincaid](https://www.ornl.gov/staff-profile/kellis-c-kincaid) | ||
- [Gerry L. Knapp](https://www.ornl.gov/staff-profile/gerald-l-knapp) | ||
- [Benjamin Stump](https://www.ornl.gov/staff-profile/benjamin-c-stump) | ||
- [Alex Plotkowski](https://www.ornl.gov/staff-profile/alex-j-plotkowski) | ||
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## Publications | ||
Some select publications using AdditiveFOAM are provided: | ||
1. [Coleman et al. "Sensitivity of Thermal Predictions to Uncertain Surface Tension Data in Laser Additive Manufacturing", J. Heat Transfer (2020) HT-19-1539](https://asmedigitalcollection.asme.org/heattransfer/article/doi/10.1115/1.4047916/1085538/Sensitivity-of-Thermal-Predictions-to-Uncertain) | ||
2. [Knapp et al. "Calibrating uncertain parameters in melt pool simulations of additive manufacturing", Comp. Mat. Sci. (2023) 111904](https://www.sciencedirect.com/science/article/abs/pii/S0927025622006152) | ||
3. [Rolchigo et al. "ExaCA: A performance portable exascale cellular automata application for alloy solidification modeling", Comp. Mat. Sci. (2022) 111692](https://www.sciencedirect.com/science/article/abs/pii/S0927025622004189) | ||
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## Repository Features | ||
| Link | Description | | ||
|-----------------------------------------------------------|------------------------------------------| | ||
| [solver](applications/solvers/additiveFoam) | Development version of the solver | | ||
| [utilities](applications/utilities) | Utilities for post-processing and code wrappers | | ||
| [tutorials](tutorials) | Tutorial cases based on [NIST AMB2018](https://www.nist.gov/ambench/amb2018-02-description) single tracks | | ||
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## Installation | ||
AdditiveFOAM is built on source code released by the OpenFOAM Foundation [openfoam.org](https://openfoam.org/), which is accessible to the public through the [OpenFOAM source code repositories at Github](https://github.com/OpenFOAM). The current supported version is **OpenFOAM-10**, which can be compiled from source code following the steps provided by the [OpenFOAM Foundation Documentation](https://openfoam.org/download/source/). | ||
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Once **OpenFOAM-10** is compiled, perform the following steps: | ||
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1. Clone the AdditiveFOAM repository into the OpenFOAM project installation directory `WM_PROJECT_INST_DIR`: | ||
```bash | ||
cd $WM_PROJECT_INST_DIR | ||
git clone https://github.com/ORNL/AdditiveFOAM.git | ||
``` | ||
2. Build the `movingHeatSource` library and the `additiveFoam` executable: | ||
```bash | ||
cd $WM_PROJECT_INST_DIR/AdditiveFOAM/applications/solvers/additiveFoam/movingHeatSource | ||
wmake libso | ||
cd $WM_PROJECT_INST_DIR/AdditiveFOAM/applications/solvers/additiveFoam | ||
wmake | ||
``` | ||
## Documentation | ||
To run an AdditiveFOAM simulation, it is recommended to perform the following steps: | ||
1. Prepare the case directory structure using a provided template: | ||
```bash | ||
mkdir -p $FOAM_RUN/additivefoam | ||
cd $FOAM_RUN/additivefoam | ||
cp -r $WM_PROJECT_INST_DIR/AdditiveFOAM/tutorials/AMB2018-02-B userCase | ||
cd userCase | ||
``` | ||
2. Modify the necessary input files according to your simulation requirements. These files include: | ||
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- `constant/`: Contains configuration and settings that define geometric and material conditions, including: | ||
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- `transportProperties`: Sets the transport properties of the material. The thermal conductivity **kappa** and specific heat **Cp** are given as temperature dependent second-order polynomials for each phase in the material. | ||
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The available phases are: | ||
- solid | ||
- liquid | ||
- powder | ||
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The remaining properties are all assumed constant throughout the simulation. | ||
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- `heatSourceDict`: Defines number, types, and paths of moving heat sources in the simulation. | ||
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The available heat sources are: | ||
- superGaussian | ||
- modifiedSuperGaussian | ||
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The available absorption models are: | ||
- constant | ||
- [Kelly](https://opg.optica.org/ao/fulltext.cfm?uri=ao-5-6-925&id=14272) | ||
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Each heat source model has the ability to be update the depth of the heat source for keyhole modeling, by setting the **transient** flag to **True** and defining an **isoValue** to track the depth of an isotherm contained within the heat source radius. An example of this usage is provided in the [multiBeam](tutorials/multiBeam) tutorial. | ||
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- `0/`: Contains the initial fields. The available fields are provided in the files: | ||
- `T`: temperature | ||
- `U`: velocity | ||
- `p_rgh`: reduced pressure | ||
- `alpha.solid`: solid volume fraction | ||
- `alpha.powder`: powder volume fraction | ||
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- `system/`: Contains simulation configuration files. | ||
- `controlDict`: Set simulation time settings and numerical parameters. | ||
- `fvSchemes`: Set the discretization schemes used to solve the governing equations | ||
- `fvSolution`: Set solution algorithms and convergence criterias. Note: fluid flow can be turned off by setting **nOuterCorrectors** to **0** in the **PIMPLE** dictionary. | ||
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3. Run the simulation: | ||
An example run script which creates a mesh, decomposes the mesh across multiple processors, and runs the AdditiveFOAM case in parallel using MPI is provided in tutorial `Allrun` script. | ||
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4. Visualize and post-process the results using **ParaView** | ||
```bash | ||
touch case.foam | ||
paraview case.foam | ||
``` | ||
### Creating Scan Path Files | ||
AdditiveFOAM supports a scan path file format that decomposes the laser path into segments that are either a) line sources or b) point sources. | ||
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| Column | Description | | ||
|----------|-----------------------------------------------------------------------------------------------------------------------------| | ||
| Column 1 | mode = 0 for line source, mode = 1 for point source | | ||
| Columns 2-4 | (x,y,z) coordinates in meters. <br>For a line (mode = 0), this is the final position of the line raster. <br>For a spot (mode = 1), this is the constant position of the laser | | ||
| Column 5 | Value for laser power in watts | | ||
| Column 6 | For a line (mode = 0), this is the velocity of the laser in meters/second. <br>For a point (mode = 1), this is the dwell time of the laser in seconds | | ||
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### Exporting ExaCA Data | ||
One feature of AdditiveFOAM is its ability to export thermal information to [ExaCA](https://github.com/ExascaleAM/ExaCA), a cellular automata (CA) code for grain growth under additive manufacturing conditions. This feature is enabled using the **execute** flag in the `constant/foamToExaCADict` file. The solidification conditions at the specified **isotherm** is tracked in the represenative volume element defined by **box** and a resolution defined by **dx**. It is recommended to track the liquidus isotherm. Users should be warned that this interpolation may cause a significant load-balancing issues if the resolution of the ExaCA data is much finer than that of the AdditiveFOAM mesh, and therefore, this feature should be used selectively. | ||
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## License | ||
AdditiveFOAM is free software: you can redistribute it and/or modify it under the terms of the GNU General Public License as published by the Free Software Foundation, either version 3 of the License, or (at your option) any later version. See the file `LICENSE` in this directory or http://www.gnu.org/licenses/, for a description of the GNU General Public License terms under which you can copy the files. | ||
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## Contact | ||
For any questions, issues, or suggestions regarding AdditiveFOAM, you can reach out to the project maintainers through the GitHub repository's issue tracker or by contacting the development team in the **Contributors** links above. | ||
We appreciate your interest in AdditiveFOAM and look forward to your contributions! |
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