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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](#Publications). | ||
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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) | ||
| - [Sam T. Reeve](https://www.ornl.gov/staff-profile/samuel-t-reeve) | ||
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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 | ||
| ### 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 | | ||
| | [tutorials](tutorials) | Tutorial cases | | ||
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| ## Documentation | ||
| [![Documentation Status][docs-badge]][docs-url] | ||
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| The documentation for `AdditiveFOAM` is hosted on [GitHub Pages](https://ornl.github.io/AdditiveFOAM/). | ||
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| ## Installation and Dependencies | ||
| [](https://github.com/OpenFOAM/OpenFOAM-10) | ||
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| ## Build and Install | ||
| AdditiveFOAM is built on source code released by the OpenFOAM Foundation [openfoam.org](https://openfoam.org/), which is available in public [OpenFOAM repositories](https://github.com/OpenFOAM). The current supported version is **OpenFOAM-10**. | ||
| AdditiveFOAM is built on source code released by the OpenFOAM Foundation [openfoam.org](https://openfoam.org/), which is available in public [OpenFOAM repositories](https://github.com/OpenFOAM). | ||
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| ### Spack install | ||
| [spack](https://spack.readthedocs.io/en/latest/) provides a simple way to install AdditiveFOAM. spack `develop` is currently required: | ||
| ```spack install additivefoam``` | ||
| [](https://github.com/spack/spack) | ||
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| ### Manual install | ||
| Alternatively, a Docker container with pre-built OpenFOAM-10 can be used: | ||
| The easiest way to install AdditiveFOAM is using [spack](https://spack.readthedocs.io/en/latest/): | ||
| ``` | ||
| docker pull openfoam/openfoam10-paraview510 | ||
| docker run -it openfoam/openfoam10-paraview510 | ||
| spack install additivefoam | ||
| ``` | ||
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| or instead OpenFOAM-10 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 available on your system, perform the following steps: | ||
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| 1. Clone the AdditiveFOAM repository into the OpenFOAM project installation directory `WM_PROJECT_USER_DIR`: | ||
| ```bash | ||
| cd $WM_PROJECT_USER_DIR | ||
| git clone https://github.com/ORNL/AdditiveFOAM.git | ||
| ``` | ||
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| If `git` is not available on your system (in the case of the OpenFOAM docker container) you can instead use: | ||
| ```bash | ||
| wget https://github.com/ORNL/AdditiveFOAM/archive/refs/heads/main.tar.gz | ||
| mkdir AdditiveFOAM | ||
| tar xzvf main.tar.gz -C AdditiveFOAM --strip-components=1 | ||
| ``` | ||
| 2. Build the `movingHeatSource` library and the `additiveFoam` executable: | ||
| ```bash | ||
| cd $WM_PROJECT_USER_DIR/AdditiveFOAM/applications/solvers/additiveFoam/movingHeatSource | ||
| wmake libso | ||
| cd $WM_PROJECT_USER_DIR/AdditiveFOAM/applications/solvers/additiveFoam | ||
| wmake | ||
| ``` | ||
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| ## Run AdditiveFOAM | ||
| 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_USER_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/LLNL/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. | ||
| See the [installation instructions](https://ornl.github.io/AdditiveFOAM/docs/installation/#installation) in the [documentation](https://ornl.github.io/AdditiveFOAM/) for other options for building `AdditiveFOAM`. | ||
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| ## Citing | ||
| If you use AdditiveFOAM in your work, please cite the Zenodo DOI [](https://doi.org/10.5281/zenodo.8034098) of the version you used as a software citation: | ||
| ```bibtex | ||
| @software{AdditiveFOAM_1.0.0, | ||
| author = {John Coleman and | ||
| Kellis Kincaid and | ||
| Gerald L. Knapp and | ||
| Benjamin Stump and | ||
| Alexander J. Plotkowski}, | ||
| title = {AdditiveFOAM: Release 1.0}, | ||
| month = jun, | ||
| year = 2023, | ||
| publisher = {Zenodo}, | ||
| version = {1.0.0}, | ||
| doi = {10.5281/zenodo.8034098}, | ||
| url = {https://doi.org/10.5281/zenodo.8034098} | ||
| } | ||
| ``` | ||
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| ## License | ||
| [](https://www.gnu.org/licenses/gpl-3.0.html) | ||
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| 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](#Contributors). | ||
| 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 directly. | ||
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| ## Contributing | ||
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| We encourage you to contribute to AdditiveFOAM! Please check the | ||
| [guidelines](CONTRIBUTING.md) on how to do so. | ||
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| We appreciate your interest in AdditiveFOAM and look forward to your contributions! | ||
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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) | ||
| - [Sam T. Reeve](https://www.ornl.gov/staff-profile/samuel-t-reeve) | ||
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| [docs-badge]: https://img.shields.io/badge/docs-latest-brightgreen.svg | ||
| [docs-url]: https://ornl.github.io/AdditiveFOAM/ |
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| //- Construct the temperature equation for the chosen time integration scheme | ||
| fvScalarMatrix TEqn(T, dimPower); | ||
| dimensionedScalar rDeltaT = 1.0 / runTime.deltaT(); | ||
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| if (explicitSolve) | ||
| { | ||
| TEqn = | ||
| ( | ||
| rho*Cp*(fvm::ddt(T) + fvc::div(phi, T)) | ||
| - fvc::laplacian(kappa, T) | ||
| - sources.qDot() | ||
| ); | ||
| } | ||
| else | ||
| { | ||
| TEqn = | ||
| ( | ||
| rho*Cp*(fvm::ddt(T) + fvm::div(phi, T)) | ||
| - fvm::laplacian(kappa, T) | ||
| - sources.qDot() | ||
| ); | ||
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| scalar coefft = 1.0; | ||
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| const word ddtScheme = mesh.schemes().ddt(T.name()); | ||
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| if | ||
| ( | ||
| (ddtScheme != "Euler") | ||
| && (ddtScheme != "backward") | ||
| && (ddtScheme != "CrankNicolson") | ||
| ) | ||
| { | ||
| FatalErrorInFunction | ||
| << "Unsupported ddtScheme " << ddtScheme | ||
| << ". Choose Euler, CrankNicolson, or backward." | ||
| << abort(FatalError); | ||
| } | ||
| else if (ddtScheme == "backward") | ||
| { | ||
| const dimensionedScalar deltaT = runTime.deltaT(); | ||
| const dimensionedScalar deltaT0 = runTime.deltaT0(); | ||
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| coefft = 1.0 + (deltaT/(deltaT + deltaT0)).value(); | ||
| } | ||
| else if (ddtScheme == "CrankNicolson") | ||
| { | ||
| scalar ocCoeff = | ||
| refCast<const fv::CrankNicolsonDdtScheme<scalar>> | ||
| ( | ||
| fv::ddtScheme<scalar>::New | ||
| ( | ||
| mesh, | ||
| mesh.schemes().ddt(ddtScheme) | ||
| )() | ||
| ).ocCoeff(); | ||
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| coefft = 1.0 + ocCoeff; | ||
| } | ||
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| Info << "thero time coefficient (coefft): " << coefft << endl; | ||
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| rDeltaT *= coefft; | ||
| } |
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