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Numerical simulation of balling behavior in metal powder bed fusion process using particle method.

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Title: Numerical simulation of balling behavior in metal powder bed fusion process using particle method.
Authors: Tokunaga, Hitoshi1 (AUTHOR) tokunaga.h@aist.go.jp, Wakai, Yuki1,2 (AUTHOR), Sato, Naoko1 (AUTHOR), Seto, Naoki1 (AUTHOR), Kajino, Satoshi1 (AUTHOR), Suzuki, Shinsuke2,3,4 (AUTHOR), Motoyama, Yuichi1 (AUTHOR), Okane, Toshimitsu1,5 (AUTHOR)
Source: International Journal of Advanced Manufacturing Technology. Feb2026, Vol. 142 Issue 11/12, p6329-6344. 16p.
Subjects: Particle methods (Numerical analysis), Discrete element method, Direct metal laser sintering, Computer simulation, Surface tension, Computational fluid dynamics
Abstract: A new computational method is proposed to simulate the balling phenomenon during powder bed fusion (PBF) metal additive manufacturing processing. The method combines the discrete element method (DEM), which simulates powder behavior, and smoothed particle hydrodynamics (SPH) method, which simulates fluid and elastoplastic behavior. Balling is a phenomenon by which spherical defects form on a product surface because of surface tension and poor wettability between the molten metal and the surrounding powder or solidified material. This phenomenon is particularly evident in materials with high surface tension, which can cause discontinuities in the melting path and which can affect manufacturing quality. Simulating such complex behavior necessitates consideration not only of the molten metal behavior (including surface tension), the metal powder and solidified metal behaviors, and the melting and solidification phenomena: it also includes their mutual interactions. The proposed method can simulate these processes. Moreover, performing simulations under conditions of various combinations of laser power and scanning speed confirm qualitatively that the proposed method captures the balling phenomenon. The proposed method can capture trends of experimentally obtained results obtained from earlier studies, i.e., under the same laser energy per unit area, the balling phenomenon becomes more likely to occur as the scanning speed and laser power increase. This approach can be a valuable tool for optimizing manufacturing conditions and for improving the quality of metal additive manufacturing processes. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 192201645
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Numerical simulation of balling behavior in metal powder bed fusion process using particle method.
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  Data: <searchLink fieldCode="AR" term="%22Tokunaga%2C+Hitoshi%22">Tokunaga, Hitoshi</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> tokunaga.h@aist.go.jp</i><br /><searchLink fieldCode="AR" term="%22Wakai%2C+Yuki%22">Wakai, Yuki</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Sato%2C+Naoko%22">Sato, Naoko</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Seto%2C+Naoki%22">Seto, Naoki</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kajino%2C+Satoshi%22">Kajino, Satoshi</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Suzuki%2C+Shinsuke%22">Suzuki, Shinsuke</searchLink><relatesTo>2,3,4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Motoyama%2C+Yuichi%22">Motoyama, Yuichi</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Okane%2C+Toshimitsu%22">Okane, Toshimitsu</searchLink><relatesTo>1,5</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Feb2026, Vol. 142 Issue 11/12, p6329-6344. 16p.
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  Data: <searchLink fieldCode="DE" term="%22Particle+methods+%28Numerical+analysis%29%22">Particle methods (Numerical analysis)</searchLink><br /><searchLink fieldCode="DE" term="%22Discrete+element+method%22">Discrete element method</searchLink><br /><searchLink fieldCode="DE" term="%22Direct+metal+laser+sintering%22">Direct metal laser sintering</searchLink><br /><searchLink fieldCode="DE" term="%22Computer+simulation%22">Computer simulation</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+tension%22">Surface tension</searchLink><br /><searchLink fieldCode="DE" term="%22Computational+fluid+dynamics%22">Computational fluid dynamics</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: A new computational method is proposed to simulate the balling phenomenon during powder bed fusion (PBF) metal additive manufacturing processing. The method combines the discrete element method (DEM), which simulates powder behavior, and smoothed particle hydrodynamics (SPH) method, which simulates fluid and elastoplastic behavior. Balling is a phenomenon by which spherical defects form on a product surface because of surface tension and poor wettability between the molten metal and the surrounding powder or solidified material. This phenomenon is particularly evident in materials with high surface tension, which can cause discontinuities in the melting path and which can affect manufacturing quality. Simulating such complex behavior necessitates consideration not only of the molten metal behavior (including surface tension), the metal powder and solidified metal behaviors, and the melting and solidification phenomena: it also includes their mutual interactions. The proposed method can simulate these processes. Moreover, performing simulations under conditions of various combinations of laser power and scanning speed confirm qualitatively that the proposed method captures the balling phenomenon. The proposed method can capture trends of experimentally obtained results obtained from earlier studies, i.e., under the same laser energy per unit area, the balling phenomenon becomes more likely to occur as the scanning speed and laser power increase. This approach can be a valuable tool for optimizing manufacturing conditions and for improving the quality of metal additive manufacturing processes. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-025-17381-y
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        Text: English
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      – SubjectFull: Discrete element method
        Type: general
      – SubjectFull: Direct metal laser sintering
        Type: general
      – SubjectFull: Computer simulation
        Type: general
      – SubjectFull: Surface tension
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      – SubjectFull: Computational fluid dynamics
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      – TitleFull: Numerical simulation of balling behavior in metal powder bed fusion process using particle method.
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            NameFull: Tokunaga, Hitoshi
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              M: 02
              Text: Feb2026
              Type: published
              Y: 2026
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