Application of bulk deformation methods for microstructural and material property improvement and residual stress and distortion control in additively manufactured components

Colegrove, Paul A.; Donoghue, Jack; Martina, Filomeno; Gu, Jianglong; Prangnell, P.B.; Hönnige, Jan

doi:10.1016/j.scriptamat.2016.10.031

Cited by 161 publications

(71 citation statements)

References 26 publications

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“…The as-deposited 2319 material, which contains large precipitates and pores, has a yield strength of 125 MPa, which can be increased to over 300 MPa with a T6treatment [39], [40]. Inter-pass rolling has been found not only to modify the internal stresses in WAAM, but also the microstructure [12], [41], [42]. The effect on the aluminium microstructure is grain refinement, a modified morphology of precipitates and the full elimination of porosity,…”

Section: Benefits Of Waam Are Dominantly the Cost Savings Through Redmentioning

confidence: 99%

Control of residual stress and distortion in aluminium wire + arc additive manufacture with rolling

Colegrove

Ganguly

Eimer

et al. 2018

Additive Manufacturing

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Rolling can control residual stress and distortion in aluminium Wire + Arc Additively Manufactured (WAAM) walls. It was applied both vertically to each deposited layer (inter-pass) and to the side of the wall after deposition is completed. Distortion was virtually eliminated with the vertical inter-pass method (unlike other metals) and inverted with side rolling. Neutron diffraction stress measurements show that the deposited wall contains constant tensile residual stresses along the build direction that reach the flow strength of the alloy in longitudinal direction. Vertical interpass rolling eliminates the distortion, but produces a multi-directional stress field, with hydrostatic compressive stresses approximately 2 mm below the top surface and hydrostatic tension 5-10 mm below the surface. Side rolling was even more effective in stress and distortion control and produced fairly uniform longitudinal compressive stresses along the wall height. An interesting by-product of the neutron diffraction measurements is the observation of a significantly larger FCC aluminium unit cell in the inter-pass rolled walls. This is a result of less copper in solid solution with the aluminium matrix, indicating greater precipitation which could have contributed to the material's improved strength.

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Section: Benefits Of Waam Are Dominantly the Cost Savings Through Redmentioning

confidence: 99%

Control of residual stress and distortion in aluminium wire + arc additive manufacture with rolling

Colegrove

Ganguly

Eimer

et al. 2018

Additive Manufacturing

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“…Colegrove et al [92] investigated bulk deformation processes applied during the AM process for property, RS, and distortion control. Rolling was applied to the WAAM of Ti-6Al-4V to apply plastic deformation to relax the RSs formed.…”

Section: Approaches To Prevent Deflectionmentioning

confidence: 99%

“…Rolling was applied to the WAAM of Ti-6Al-4V to apply plastic deformation to relax the RSs formed. Depending on the orientation of the roller with respect to the part (shown in Figure 24), the distortion and RS could be nearly eliminated from about 550 MPa to less than 200 MPa [92].…”

Section: Approaches To Prevent Deflectionmentioning

confidence: 99%

“…It was determined that depositing additional material after the completion of each layer was the most successful, with 91% of the bending distortion eliminated (see Figures 22 and 23) [91]. Colegrove et al [92] investigated bulk deformation processes applied during the AM process for property, RS, and distortion control. Rolling was applied to the WAAM of Ti-6Al-4V to apply plastic deformation to relax the RSs formed.…”

Section: Approaches To Prevent Deflectionmentioning

confidence: 99%

“…Investigations of bulk deformation processes (rolling) applied to AM components during the build process as a slotted roller in the build direction (a), flat rolling ahead of the heat source in the build direction (b) or in the transverse direction (c), and an inverted profile roller for thick regions (d)[92].…”

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On Residual Stress Development, Prevention, and Compensation in Metal Additive Manufacturing

Carpenter

Tabei

2020

Materials

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One of the most appealing qualities of additive manufacturing (AM) is the ability to produce complex geometries faster than most traditional methods. The trade-off for this advantage is that AM parts are extremely vulnerable to residual stresses (RSs), which may lead to geometrical distortions and quality inspection failures. Additionally, tensile RSs negatively impact the fatigue life and other mechanical performance characteristics of the parts in service. Therefore, in order for AM to cross the borders of prototyping toward a viable manufacturing process, the major challenge of RS development must be addressed. Different AM technologies contain many unique features and parameters, which influence the temperature gradients in the part and lead to development of RSs. The stresses formed in AM parts are typically observed to be compressive in the center of the part and tensile on the top layers. To mitigate these stresses, process parameters must be optimized, which requires exhaustive and costly experimentations. Alternative to experiments, holistic computational frameworks which can capture much of the physics while balancing computational costs are introduced for rapid and inexpensive investigation into development and prevention of RSs in AM. In this review, the focus is on metal additive manufacturing, referred to simply as “AM”, and, after a brief introduction to various AM technologies and thermoelastic mechanics, prior works on sources of RSs in AM are discussed. Furthermore, the state-of-the-art knowledge on RS measurement techniques, the influence of AM process parameters, current modeling approaches, and distortion prevention approaches are reported.

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Modified Inherent Strain Method for Predicting Residual Deformation and Stress in Metal Additive Manufacturing

Liang

Dong

2023

Additive Manufacturing Technology

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Application of bulk deformation methods for microstructural and material property improvement and residual stress and distortion control in additively manufactured components

Cited by 161 publications

References 26 publications

Control of residual stress and distortion in aluminium wire + arc additive manufacture with rolling

Control of residual stress and distortion in aluminium wire + arc additive manufacture with rolling

On Residual Stress Development, Prevention, and Compensation in Metal Additive Manufacturing

Modified Inherent Strain Method for Predicting Residual Deformation and Stress in Metal Additive Manufacturing

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