[Supplementary materials] Multiphysics Simulation of Single Pulse Laser Powder Bed Fusion: Comparison of Front Capturing and Front Tracking Methods

Two multiphysical models of Laser Powder Bed Fusion (LPBF) at melt pool scale are compared. The first one is based on the Level-Set (LS) front capturing method, implemented in a C++ code. The second one is developed with the commercial software COMSOL Multiphysics®, and is based on the Arbitrary Lagrangian Eulerian front tracking method.The objective of this study is to assess to what extent front description methods may limit or bias physical representativeness of multiphysics modelling of LPBF process.Therefore, the two codes are confronted on two test cases of increasing complexity (static laser shooting on bare plate and on powder bed), and quantitative data are systematically compared. This study gives clues on how to calibrate numerical parameters such as LS interface thickness and how to modify the classical Continuum Force Formulation in order to get the best physical representativeness. The data provided here can be used by any researcher willing to verify their own model of thermal laser applications.