Analysis of distortion during laser metal deposition of large parts

Turichin, Gleb; Zemlyakov, Evgeniy; Babkin, Konstantin; Ivanov, S. Yu.; Vildanov, Artur

doi:10.1016/j.procir.2018.08.068

Cited by 30 publications

(13 citation statements)

References 5 publications

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“…The high power of the laser source should ensure and maintain a high melting rate of the powder in order to ensure high process productivity up to 1.5–2.5 kg/h [ 4 ]. However, this can lead both to the appearance of instability of the wall formation described in [ 7 ], and to a deviation from the specified dimensions [ 8 ]. A large number of important parameters of the processing mode, and the danger of leaving the process in the zone of unstable formation, greatly complicate the selection of technological parameters by the experimental method.…”

Section: Introductionmentioning

confidence: 99%

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

et al. 2021

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This article deals with the theoretical issues of the formation of a melt pool during the process of direct laser deposition. The shape and size of the pool depends on many parameters, such as the speed and power of the process, the optical and physical properties of the material, and the powder consumption. On the other hand, the influence of the physical processes occurring in the material on one another is significant: for instance, the heating of the powder and the substrate by laser radiation, or the formation of the free surface of the melt, taking into account the Marangoni effect. This paper proposes a model for determining the size of the melt bath, developed in a one-dimensional approximation of the boundary layer flow. The dimensions and profile of the surface and bottom of the melt pool are obtained by solving the problem of convective heat transfer. The influence of the residual temperature from the previous track, as well as the heat from the heated powder of the gas–powder jet, taking into account its spatial distribution, is considered. The simulation of the size and shape of the melt pool, as well as its free surface profile for different alloys, is performed with 316 L steel, Inconel 718 nickel alloy, and VT6 titanium alloy

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Section: Introductionmentioning

confidence: 99%

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

et al. 2021

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“…This solution was chosen for the investigation of substrate and component deformations during deposition. Indeed, due to residual tensions, the component tends to shrink in the circumferential direction, resulting in radial shrinkage as well [30]. As a result, the substrate should bend towards the center.…”

Section: Case Study Definition and Realizationmentioning

confidence: 99%

Comparison between Eight-Axis Articulated Robot and Five-Axis CNC Gantry Laser Metal Deposition Machines for Fabricating Large Components

Maffia

Chiappini²,

Maggiani³

et al. 2023

Applied Sciences

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Laser metal deposition (LMD) is an additive manufacturing (AM) process capable of producing large components for the aerospace and oil and gas industries. This is achieved by mounting the deposition head on a motion system, such as an articulated robot or a gantry computer numerical control (CNC) machine, which can scan large volumes. Articulated robots are more flexible and less expensive than CNC machines, which on the other hand, are more accurate. This study compares two LMD systems with different motion architectures (i.e., an eight-axis articulated robot and a five-axis CNC gantry machine) in producing a large gas turbine axisymmetric component. The same process parameters were applied to both machines. The deposited components show no significant differences in geometry, indicating that the different performances in terms of accuracy of the two machines do not influence the outcome. The findings indicate that LMD can consistently produce large-scale axisymmetric metal components with both types of equipment. For such an application, the user has the option of using an articulated robot when flexibility and cost are essential, such as in a research context, or a CNC machine where ease of programming and process standardization are important elements, such as in an industrial environment.

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“…According to References [25,26], the shape of the deposited bead on an inclined surface can be determined by Formula (4); however, the system of Equation (5) for determining the calculated parameters should take into account the angle of inclination of the surface A 2 D 2 to the X-axis and transform to the following:…”

Section: ( )mentioning

confidence: 99%

“…The process of direct laser deposition is one of the types of additive manufacturing technologies that allows for the production parts of complex geometric shape [1] from various materials [2][3][4], due to melting and crystallization of the filler material under the action of laser radiation directly in the processing zone, in situ. The deposited parts can be divided into three groups: thin-walled parts [5] deposited in one pass, thick-walled parts [6] with a width of several passes and parts manufactured in a combined way. The presented work is devoted to the problem of deposition walls with a thickness of several passes.…”

Section: Introductionmentioning

confidence: 99%

Numerical Estimation of the Geometry of the Deposited Layers during Direct Laser Deposition of Multi-Pass Walls

Udin

Valdaytseva

Kislov

2021

Metals

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Direct laser deposition (DLD) is a promising additive technology that allows for the rapid and cheap production of metal parts of complex geometry in various sectors of mechanical engineering. Thick-walled metal structures occupy a significant part in mechanical engineering. The purpose of this study was to develop and test an algorithm for predicting the geometry of deposited multi-pass walls. To achieve this goal, the main interrelated processes involved in the formation of a multi-pass wall were described—the process of laser radiation propagation, the process of heat transfer and the process of bead formation. To construct the calculation algorithm, five characteristic types of beads are identified. For these five types, the features of the bead formation and the features of the laser radiation intensity distribution are described. The calculated data were verified. A good match of the calculated data with the geometry of the deposited walls from AISI321 steel, Inconel718 and Ti-6Al-4V alloys was obtained.

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Analysis of distortion during laser metal deposition of large parts

Cited by 30 publications

References 5 publications

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

Comparison between Eight-Axis Articulated Robot and Five-Axis CNC Gantry Laser Metal Deposition Machines for Fabricating Large Components

Numerical Estimation of the Geometry of the Deposited Layers during Direct Laser Deposition of Multi-Pass Walls

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