Analytical Modeling of Residual Stress in Laser Powder Bed Fusion Considering Part’s Boundary Condition

Mirkoohi, Elham; Tran, Hong Chuong; Lo, Yu Lung; Chang, Yi-Chih; Lin, Hung Yu; Liang, Steven Y.

doi:10.3390/cryst10040337

Cited by 25 publications

(12 citation statements)

References 40 publications

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“…Moreover, the molecular dynamic method was used to investigate the effects of crystalline form, temperature, and grain orientation of columnar grains on the mechanical properties of SLM aluminum, which showed that reasonable control of the grain orientation can improve the tensile strength of the AM materials [70]. The Green's function of stresses was used to present the thermal stresses and the Johnson-Cook flow stress model was used to predict the yield surface of the part under repeated heating and cooling [71]. A crystal plasticity finite element model was proposed to simulate the stress-strain response and fatigue crack initiation life of AM IN718 with different microstructures under tensile loadings [72].…”

Section: Experiments and Numerical Simulationsmentioning

confidence: 99%

A Review of the Latest Developments in the Field of Additive Manufacturing Techniques for Nuclear Reactors

Zhang

et al. 2022

Crystals

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This review paper provides insights the into current developments in additive manufacturing (AM) techniques. The comprehensive presentations about AM methods, material properties (i.e., irradiation damage, as-built defects, residual stresses and fatigue fracture), experiments, numerical simulations and standards are discussed as well as their advantages and shortages for the application in the field of nuclear reactor. Meanwhile, some recommendations that need to be focused on are presented to advance the development and application of AM techniques in nuclear reactors. The knowledge included in this paper can serve as a baseline to tailor the limitations, utilize the superiorities and promote the wide feasibilities of the AM techniques for wide application in the field of nuclear reactors.

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Section: Experiments and Numerical Simulationsmentioning

confidence: 99%

A Review of the Latest Developments in the Field of Additive Manufacturing Techniques for Nuclear Reactors

Zhang

et al. 2022

Crystals

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“…For FLM ("Fused Layer Modelling") as well as in laser-based LBM ("laser beam melting") and EBM ("electron beam melting") processes, samples with different geometries are used in product/process development. The use of a rectangular parallelepiped [9], a tensile test geometry [10,11], a solid cylindrical rod [12], and the combined use of a cube and a parallelepiped [13] are known for the evaluation of AMprocesses. In the following, requirements and criteria are described which are placed on a sample for the assessment of the additive-subtractive process chain using the example of the laser metal wire deposition (LMWD) process.…”

Section: Test Sample Geometrymentioning

confidence: 99%

Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

Becker

Boley

Eisseler

et al. 2021

Prod. Eng. Res. Devel.

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This paper describes the interdependence of additive and subtractive manufacturing processes using the production of test components made from S Al 5356. To achieve the best possible part accuracy and a preferably small wall thickness already within the additive process, a closed loop process control was developed and applied. Subsequent machining processes were nonetheless required to give the components their final shape, but the amount of material in need of removal was minimised. The effort of minimising material removal strongly depended on the initial state of the component (wall thickness, wall thickness constancy, microstructure of the material and others) which was determined by the additive process. For this reason, knowledge of the correlations between generative parameters and component properties, as well as of the interdependency between the additive process and the subsequent machining process to tune the former to the latter was essential. To ascertain this behaviour, a suitable test part was designed to perform both additive processes using laser metal wire deposition with a closed loop control of the track height and subtractive processes using external and internal longitudinal turning with varied parameters. The so manufactured test parts were then used to qualify the material deposition and turning process by criteria like shape accuracy and surface quality.

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“…If the stress passes the yield strength, upon unloading (cooling in this situation) some amount of stress remains in the body, which is known as RS. The RS is inherent in all the AM parts and can be reduced or eliminated with proper control and optimization of process parameters or post-processing techniques such as pitting, and heat treatment since it has an elastic nature [34,35].…”

Section: Mechanical Analysismentioning

confidence: 99%

Analytical Modeling of Residual Stress in Laser Powder Bed Fusion Considering Volume Conservation in Plastic Deformation

Mirkoohi

Li²,

Garmestani

et al. 2020

Modelling

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Residual stress (RS) is the most challenging problem in metal additive manufacturing (AM) since the build-up of high tensile RS may influence the fatigue life, corrosion resistance, crack initiation, and failure of the additively manufactured components. While tensile RS is inherent in all the AM processes, fast and accurate prediction of the stress state within the part is extremely valuable and results in optimization of the process parameters to achieve a desired RS and control of the build process. This paper proposes a physics-based analytical model to rapidly and accurately predict the RS within the additively manufactured part. In this model, a transient moving point heat source (HS) is utilized to determine the temperature field. Due to the high temperature gradient within the proximity of the melt pool area, the material experiences high thermal stress. Thermal stress is calculated by combining three sources of stresses known as stresses due to the body forces, normal tension, and hydrostatic stress in a homogeneous semi-infinite medium. The thermal stress determines the RS state within the part. Consequently, by taking the thermal stress history as an input, both the in-plane and out of plane RS distributions are found from the incremental plasticity and kinematic hardening behavior of the metal by considering volume conservation in plastic deformation in coupling with the equilibrium and compatibility conditions. In this modeling, material properties are temperature-sensitive since the steep temperature gradient varies the properties significantly. Moreover, the energy needed for the solid-state phase transition is reflected by modifying the specific heat employing the latent heat of fusion. Furthermore, the multi-layer and multi-scan aspects of metal AM are considered by including the temperature history from previous layers and scans. Results from the analytical RS model presented excellent agreement with XRD measurements employed to determine the RS in the Ti-6Al-4V specimens.

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Analytical Modeling of Residual Stress in Laser Powder Bed Fusion Considering Part’s Boundary Condition

Cited by 25 publications

References 40 publications

A Review of the Latest Developments in the Field of Additive Manufacturing Techniques for Nuclear Reactors

A Review of the Latest Developments in the Field of Additive Manufacturing Techniques for Nuclear Reactors

Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

Analytical Modeling of Residual Stress in Laser Powder Bed Fusion Considering Volume Conservation in Plastic Deformation

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