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The powder-bed electron-beam additive manufacturing (EBAM) process is a new
additive manufacturing (AM) technology in which the metal powder is melted in vacuum utilizing
a high-energy heat source to fabricate metallic parts in a layer by layer manner. Despite the unique
advantages of designing complex geometry and tooling-free manufacturing, there are still
considerable challenges in the EBAM, e.g., obtaining desired metallurgical behavior, part
accuracy, reliability, and quality consistency. Therefore, a better understanding of the thermofluid
and mechanical properties of the EBAM process is indispensable to meet the challenges. In
this study, transient computational fluid dynamics (CFD) modeling of Ti-6Al-4V melt pool has
been done using ANSYS Fluent 15.0 to characterize the process parameters associated with the
EBAM process including a realistic melt pool geometry. The dynamics and the solidification of
the melt pool have been investigated numerically and results for cooling rate, variation in density,
pressure, velocities, and liquid fraction have been obtained to enhance of the analysis.