A novel multiscale thermal analysis numerical tool has been developed to address the micro–macro interactions involved in localized melting and sintering processes, such as laser sintering of metals exhibiting nonlinear thermal response. The method involves extension of a feed-forward dynamic adaptive mesh refinement and derefinement finite-element framework to incorporate nonlinear thermal phenomenon in the vicinity of the energy source and further reduce computational time and complexity when simulating spatiotemporally periodic problems posed by metal laser sintering. The thermal and microstructural predictions computed using this framework are in good agreement with the thermal contours measured using a forward-looking infrared (FLIR) imaging system and microstructures observed using an optical microscope.

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