Initial AdditiveFOAM Release

Co-authored-by: Kincaid, Kellis <kincaidkc@ornl.gov> Co-authored-by: Knapp, Gerry <knappgl@ornl.gov>
ORNL · Jun 13, 2023 · 8ca7546 · 8ca7546
1 parent 68fa8b2
commit 8ca7546
Show file tree

Hide file tree

Showing 103 changed files with 7,340 additions and 0 deletions.
diff --git a/.gitignore b/.gitignore
@@ -0,0 +1,45 @@
+# Editor and misc backup files - anywhere
+*~
+.*~
+.*.swp
+*.bak
+*.bak[0-9][0-9]
+\#*\#
+
+# File-browser settings - anywhere
+.directory
+
+# CVS recovered versions - anywhere
+.#*
+
+# Objects and archives - anywhere
+*.[oa]
+*.la
+*.so
+
+# Derived files
+lex.yy.c
+
+# Corefiles
+core
+
+# Dependency files - anywhere
+*.dep
+
+# lnInclude (symlink) directories - anywhere
+lnInclude
+
+# Build directories - anywhere
+linux*Clang*/
+linux*Gcc*/
+linux*Icc*/
+solaris*Gcc*/
+SunOS*Gcc*/
+platforms/
+
+# Source packages - anywhere
+*.tar.bz2
+*.tar.gz
+*.tar
+*.tgz
+*.gtgz
diff --git a/CITATION.bib b/CITATION.bib
@@ -0,0 +1,9 @@
+@software{john_coleman_2023_doi,
+  author       = {John Coleman},
+  title        = {AdditiveFOAM},
+  version      = {0.0},
+  date         = {June 2023},
+  publisher    = {Zenodo},
+  url          = {},
+  doi          = {}
+}
diff --git a/LICENSE b/LICENSE
@@ -1,4 +1,15 @@
                     GNU GENERAL PUBLIC LICENSE
+
+ Copyright (C) 2011-2017 OpenFOAM Foundation
+ Copyright (C) 2023      Oak Ridge National Laboratory
+
+ You may use, distribute and copy AdditiveFOAM under the terms
+ of GNU General Public License version 3, which is displayed below, or
+ (at your option) any later version.
+
+-------------------------------------------------------------------------
+
+                    GNU GENERAL PUBLIC LICENSE
                        Version 3, 29 June 2007
 
  Copyright (C) 2007 Free Software Foundation, Inc. <https://fsf.org/>

diff --git a/README.md b/README.md
@@ -0,0 +1,117 @@
+# 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.
+
+## Citing
+If you use AdditiveFoam in your work, please cite the [source code](CITATION.bib). Also, please consider citing relevant AdditiveFOAM **Publications** listed below.
+
+## 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)
+
+## 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)
+
+## 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 |
+
+## 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/).
+
+Once **OpenFOAM-10** is compiled, perform the following steps:
+
+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:
+
+   - `constant/`: Contains configuration and settings that define geometric and material conditions, including:
+
+      - `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.
+
+         The available phases are:
+         - solid
+         - liquid
+         - powder
+
+         The remaining properties are all assumed constant throughout the simulation.
+
+      - `heatSourceDict`: Defines number, types, and paths of moving heat sources in the simulation.
+
+         The available heat sources are:
+         - superGaussian
+         - modifiedSuperGaussian
+
+         The available absorption models are:
+         - constant
+         - [Kelly](https://opg.optica.org/ao/fulltext.cfm?uri=ao-5-6-925&id=14272)
+
+         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.
+
+   - `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
+
+   - `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.
+
+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.
+
+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.
+
+| 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                         |
+
+### 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.
+
+## 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.
+
+## 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!