PSI - Issue 83

Available online at www.sciencedirect.com

ScienceDirect

Procedia Structural Integrity 83 (2026) 130–137

© 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ESIAM26 organizers Keywords: Surrogate model (SM), Reduced order model (ROM), Additive manufacturing (AM), Finite element method (FEM), Powder bed fusion using a laser beam (PBF-LB), Distortion. Abstract Metal Additive Manufacturing (AM) offers unique design opportunities but is still limited by the high cost and time of process development, where distortion, residual stress, and geometric inaccuracies remain critical challenges. This work introduces an integrated methodology that combines finite element simulations, surrogate modelling, and experimental 3D printing to enable efficient and accurate process prediction. High-fidelity thermo-mechanical simulations are validated through benchmark twin cantilever builds, and their results are used to generate reduced-order surrogate models. These models maintain prediction accuracy while reducing computational time by several orders of magnitude compared to full simulations. The framework captures the influence of key parameters such as laser power, scan speed, and preheating temperature, providing fast and reliable predictions of part deflection. The proposed approach establishes how physics-based surrogate models can accelerate process optimization, reduce costly trial-and-error iterations, and pave the way for digital twins that support robust qualification of metal AM components. The fourth European Conference on the Structural Integrity of Additively Manufactured Materials (ESIAM26) Simulations and Surrogate Modelling for Efficient Process Prediction in Metal Additive Manufacturing C. Mallor a * , V. Zambrano a , J.R. Valdés a , S. Calvo a a Area of Research and Development, Instituto Tecnológico de Aragón, María de Luna, 8-50018 Zaragoza, Spain.

* Corresponding author. Tel.: +34-976-01-00-00; fax: +34-976-01-18-18. E-mail address: cmallor@ita.es

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ESIAM26 organizers 10.1016/j.prostr.2026.07.015