A Computational Efficient Approach to Compute Temperature for Energy Beam Additive Manufacturing

Ou, Chun-Yu; Liu, C. Richard

doi:10.1115/1.4050465

Cited by 2 publications

(1 citation statement)

References 19 publications

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“…That numerical approach demonstrated excellent computational performance compared to ABAQUS ® . Likewise, an innovative scheme was proposed to compute an effective computation zone as a boundary condition to save calculation time up to 10 4 of the traditional FEM scheme [ 24 ]. Ma et al [ 25 ] presented a computationally efficient parallel computing program “JWRIAN-hybrid” based on a combination of an accelerated explicit and implicit FEM scheme for temperature, residual stress, and distortion prediction in welding structures [ 25 ].…”

Section: Introductionmentioning

confidence: 99%

Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

et al. 2023

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Laser cladding has emerged as a promising technique for custom-built fabrications, remanufacturing, and repair of metallic components. However, frequent melting and solidification in the process cause inevitable residual stresses that often lead to geometric discrepancies and deterioration of the end product. The accurate physical interpretation of the powder consolidation process remains challenging. Thermomechanical process simulation has the potential to comprehend the layer-by-layer additive process and subsequent part-scale implications. Nevertheless, computational accuracy and efficacy have been serious concerns so far; therefore, a hybrid FEM scheme is adopted for efficient prediction of the temperature field, residual stress, and distortion in multilayer powder-fed laser cladding of Inconel®718. A transient material deposition with powder material modeling is schematized to replicate the fabrication process. Moreover, simulation results for residual stress and distortion are verified with in-house experiments, where residual stress is measured with XRD (X-Ray Diffraction) and geometric distortion is evaluated with CMM (Coordinate Measuring Machine). A maximum tensile residual stress of 373 ± 5 MPa is found in the vicinity of the layer right in the middle of the substrate and predicted results are precisely validated with experiments. Similarly, a 0.68 ± 0.01 mm distortion is observed with numerical simulation and showed a precise agreement with experimental data for the same geometry and processing conditions. Conclusively, the implemented hybrid FEM approach demonstrated a robust and accurate prediction of transient temperature field, residual stresses, and geometric distortion in the multilayer laser cladding of Inconel®718.

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Section: Introductionmentioning

confidence: 99%

Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

et al. 2023

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A New General Methodology to Create Continuous Cooling Transformation Diagrams for Materials Fabricated by Additive Manufacturing

Liu

2021

Journal of Manufacturing Science and Engineering

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Additive manufacturing (AM) is a manufacturing method that can build high-strength materials layer-by-layer to form complex geometries. Previous studies have reported large variations in the mechanical properties of materials made by this process. One of the key factors that may contribute to variations within and among parts made by this process is a difference in the material's microstructural phase and composition. A continuous cooling transformation (CCT) diagram is a useful tool that can be used with a thermal model for microstructure design and manufacturing process control. However, traditional CCT diagrams are developed based on slow and monotonic cooling processes such as furnace cooling and air cooling, which are greatly different from the repetitive heating and cooling processes in AM. In this study, a new general methodology is presented to create CCT diagrams for materials fabricated by AM. We showed that the effect of the segmented duration within the critical temperature range, which induced precipitate formation, could be cumulative. As multiple cooling processes occurred in a short time, and the temperature drops at a high cooling rate, a constant average cooling rate was assumed when constructing the CCT diagram. Inconel 718 parts fabricated by selective laser melting were analyzed. The key factor contributing to phase transformation was identified as the accumulated duration within the critical temperature range. The presented methodology demonstrated the capability of combining a thermal model and experimental observation to quantitatively predict phase transformation and could be used to design microstructures and control AM processes.

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A Computational Efficient Approach to Compute Temperature for Energy Beam Additive Manufacturing

Cited by 2 publications

References 19 publications

Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718

A New General Methodology to Create Continuous Cooling Transformation Diagrams for Materials Fabricated by Additive Manufacturing

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