A hybrid multi-physics and multi-zones simulation framework for laser-based manufacturing processes

A hybrid multi-physics and multi-zones simulation framework for laser-based manufacturing processes | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article A hybrid multi-physics and multi-zones simulation framework for laser-based manufacturing processes Yabo JIA, Jean-Michel Bergheau This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7506616/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract During the modelling of laser-based manufacturing processes (welding, additive manufacturing), thermal-fluid models solving heat transfer, free surface evolution, and transport phenomena within the melt pool, are highly predictive but computationally expensive. To reduce the computational cost, an efficient framework, using Arbitrary Lagrangian-Eulerian (ALE) based finite element method, is developed to accelerate the thermal-fluid simulations in part-scale geometry. Instead of conducting thermal-fluid simulation in entire modeling domain, the framework propose an optimised solution to reduce the total degrees of freedom (DOF) consequently computational time by: (1) solving thermal-fluid problem (mass/energy/momentum conservation equations) only in the small moving fluidic zone containing the melting pool; (2) solving heat transfer problem (energy conservation equation) in a part of zone outside fluidic zone; (3) making the elements far from heating source (smaller than user-defined active temperature) to be non-active and fast evaluating the temperature evolution by an explicit time integration schema. Finally, the proposed framework has been successfully applied to laser welding and laser-based Direct Energy Deposition (DED) simulations, demonstrating good agreement with experimental and numerical benchmarks. For the given examples, the proposed framework is about 5 times more efficient than the classical ALE model. Multi-physics model Finite Element Method ALE Laser welding Additive manufacturing Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7506616","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":531917649,"identity":"66a6ab1d-2d37-4803-a52f-d1aad770ed24","order_by":0,"name":"Yabo JIA","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAxUlEQVRIiWNgGAWjYFACHhCWYOBnYGBjqGCQI0GLZANQyxkGY2K1AIHBAWK1GBw/e/ABg4yFvPGN3GMPDjAY5BPWciYv2QDoMMNtN/LSgTYZWDYQ1HIgx0wCqIVx240cM+kPDH8MCNty/g1Yi/3mGUC9QFuI0HIDYkviBglitUjeeJdskMAjkTzjzLs0iQMGRGjhO5978MHHnjrb/vbcYxIHKojQonAASCT2gJigCCKsgYFBvgFE/oBpGQWjYBSMglGABQAAeZ44rwR5lAwAAAAASUVORK5CYII=","orcid":"","institution":"Polytechnic University of Hauts-de-France","correspondingAuthor":true,"prefix":"","firstName":"Yabo","middleName":"","lastName":"JIA","suffix":""},{"id":531917650,"identity":"86b4dda8-0fb9-4a11-8c54-f386198f87f1","order_by":1,"name":"Jean-Michel Bergheau","email":"","orcid":"","institution":"École Nationale d'Ingénieurs de Saint-Étienne","correspondingAuthor":false,"prefix":"","firstName":"Jean-Michel","middleName":"","lastName":"Bergheau","suffix":""}],"badges":[],"createdAt":"2025-09-01 09:23:22","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7506616/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7506616/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":100905292,"identity":"e4159884-a9c8-4278-a59d-4433df49d164","added_by":"auto","created_at":"2026-01-22 15:41:23","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1941896,"visible":true,"origin":"","legend":"","description":"","filename":"snarticle.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7506616/v1_covered_754be4f3-e890-42ea-b0b1-7d90c5faf7be.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"A hybrid multi-physics and multi-zones simulation framework for laser-based manufacturing processes","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Multi-physics model, Finite Element Method, ALE, Laser welding, Additive manufacturing","lastPublishedDoi":"10.21203/rs.3.rs-7506616/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7506616/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"During the modelling of laser-based manufacturing processes (welding, additive manufacturing), thermal-fluid models solving heat transfer, free surface evolution, and transport phenomena within the melt pool, are highly predictive but computationally expensive. To reduce the computational cost, an efficient framework, using Arbitrary Lagrangian-Eulerian (ALE) based finite element method, is developed to accelerate the thermal-fluid simulations in part-scale geometry. Instead of conducting thermal-fluid simulation in entire modeling domain, the framework propose an optimised solution to reduce the total degrees of freedom (DOF) consequently computational time by: (1) solving thermal-fluid problem (mass/energy/momentum conservation equations) only in the small moving fluidic zone containing the melting pool; (2) solving heat transfer problem (energy conservation equation) in a part of zone outside fluidic zone; (3) making the elements far from heating source (smaller than user-defined active temperature) to be non-active and fast evaluating the temperature evolution by an explicit time integration schema. Finally, the proposed framework has been successfully applied to laser welding and laser-based Direct Energy Deposition (DED) simulations, demonstrating good agreement with experimental and numerical benchmarks. For the given examples, the proposed framework is about 5 times more efficient than the classical ALE model.","manuscriptTitle":"A hybrid multi-physics and multi-zones simulation framework for laser-based manufacturing processes","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-01-22 15:40:35","doi":"10.21203/rs.3.rs-7506616/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"18da979a-f4ac-4b91-8d0f-fc6d81e07322","owner":[],"postedDate":"January 22nd, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2026-01-22T15:40:36+00:00","versionOfRecord":[],"versionCreatedAt":"2026-01-22 15:40:35","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7506616","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7506616","identity":"rs-7506616","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}