ORNL/AdditiveFOAM: Release 2.0.0

AdditiveFOAM 2.0.0 is a major release built for OpenFOAM-14. It introduces a general projected heat- source framework, measured beam-profile tooling, automated heat-source calibration, predictive mesh refinement, and substantially expanded tutorials and documentation.

Important: AdditiveFOAM 2.0.0 requires OpenFOAM-14. Existing 1.x cases must migrate their heat-source dictionaries to the new nested model interface.

Highlights

• Ported AdditiveFOAM and its build, solver, utilities, function objects, tests, and tutorials to OpenFOAM-14.
• Added a general projected heat-source model composed of selectable planar profiles and axial projections.
• Added super-Gaussian, nLight AFX, and tabulated planar profiles with exponential axial projection.
• Added rotated elliptical analytic profiles and selectable e2 or secondMoment radius definitions.
• Added profile normalization, centroid, covariance, azimuth, and principal-axis D4Sigma metrics.
• Added configurable area-equivalent, major-axis, or minor-axis D4Sigma width references and constant or isotherm depth references.
• Added model-specific integration bounds that retain a specified tolerance of analytical source power.
• Added predictive dynamic-refinement strategies, including the targetCellLoad model.
• Added reusable AlSi10Mg, IN625, SS316L, and nLight AFX configuration files.

Heat-source calibration

The new calibrateHeatSource workflow calibrates the projected axial closure directly against measured melt-pool depths. It includes:

• Resumable simulation caching and provenance fingerprints.
• Adaptive response-curve construction.
• Deterministic posterior quadrature for local parameter inference.
• Propagation of local uncertainty through the global robust fit.
• Bootstrap uncertainty bands.
• CSV summaries and PDF reports.
• A complete SS316L calibration tutorial using a measured tabulated beam profile.

Python 3.10–3.12 and the pinned packages in requirements.txt are required only for calibration and plotting utilities.

Beam-profile utilities

• Added primesToAdditiveFoam for converting PRIMES CSV exports to normalized AdditiveFOAM profiles.
• Added reconstruction of the PRIMES calculation ROI, coordinate-preserving cropping, and converted- versus-reported beam statistics.
• Added tabulatedProfileInfo for reporting profile integral, centroid, D4Sigma, and azimuth.
• Tabulated profiles now derive their normalization, support, and reference dimensions directly from the profile table.

Correctness and reliability

• Made heat sources one-sided and consistent with their analytical normalization.
• Synchronized source depth, shape parameters, normalization, and bounds before beam subcycling.
• Preserved the active-power fraction when a solver step crosses the end of a scan path.
• Restricted transient isotherm-depth calculations to source support below the beam plane.
• Corrected projected-source bounds and a modified super-Gaussian endpoint singularity.
• Preserved explicitly configured Kelly aspectRatioSwitch values and applied etaMin as a lower bound.
• Corrected thermodynamic-path bracketing, refinement updates, MRF flux handling, and boundary initialization.

Tutorials and workflows

Expanded or updated tutorials for:

• AMB2018-02-B
• Multi-beam processing
• Multi-layer powder-bed fusion
• nLight AFX beam profiles
• Tabulated PRIMES profiles
• Projected heat-source calibration

Helper scripts for layer execution, reconstruction, absorbed-power plotting, melt-pool dimensions, and solidification data are now available through the AdditiveFOAM bin directory.

Upgrading from 1.x

• Source OpenFOAM-14 before sourcing AdditiveFOAM/etc/bashrc, then rebuild with ./Allwmake.
• Replace legacy *Coeffs dictionaries with nested absorption, heatSource, profile, projection, and refinement dictionaries containing a model entry.
• Select projected Gaussian, nLight AFX, and tabulated profiles through heatSource { model projected; }.
• Replace projected coefficients A and B with nSlope and nIntercept.
• Specify analytic radius as a two-dimensional value and depth separately.
• Remove manually supplied lateral dimensions from tabulated profiles.
• Update scripts that referenced the former multi-layer utility locations to use the commands in bin.

Full changelog: 1.2.0…2.0.0 (https://github.com/ORNL/AdditiveFOAM/compare/1.2.0...2.0.0)