Controlling of residual stress in additive manufacturing of Ti6Al4V by finite element modeling

Vastola, G.; Zhang, G.; Pei, Qing‐Xiang; Zhang, Y.-W.

doi:10.1016/j.addma.2016.05.010

Cited by 147 publications

(92 citation statements)

References 21 publications

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“…Many authors in the research are focused on the effects of Ti6Al4V processing technology on its mechanical, fatigue properties, surface quality after machining, and so on [20][21][22][23][24][25][26]. In particular, the influence of the building direction in additive technologies is observed.…”

Section: Research Activities Related To Dmls/slm Of Ti6al4vmentioning

confidence: 99%

Influence of Build Orientation, Heat Treatment, and Laser Power on the Hardness of Ti6Al4V Manufactured Using the DMLS Process

Guzanová

Ižaríková

Brezinová

et al. 2017

Metals

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This contribution is focused on the influence of build orientation on hardness of materials sintered using direct metal laser sintering (DMLS) technology. It builds on the current research works that has monitored the influence of build orientation on a fatigue life, mechanical properties, roughness after machining, etc. In the mentioned work, a slight influence of build orientation on the above properties was shown. The hardness was measured on a Ti6Al4V alloy which was made of powder by DMLS technology. The individual materials were sintered at different laser powers, then annealed to remove internal stresses. Part of the experiment examined the metallographic analysis of materials in the direction perpendicular to the sintered layers and parallel with the sintered layers. Microhardness was measured on metallographic cross-sections and the results were statistically processed. The influence of laser power on a respective material hardness was assessed by one-way analysis of variance (ANOVA), a comparison of the hardness between sintered and sintered-annealed samples, as well as the comparison of hardness in the two considered directions was performed by t-test and F-test. A statistically significant difference in the hardness of the materials prepared at different laser powers was found. The influence of heat treatment, as well as the direction of material building also showed a statistically significant difference.

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Section: Research Activities Related To Dmls/slm Of Ti6al4vmentioning

confidence: 99%

Influence of Build Orientation, Heat Treatment, and Laser Power on the Hardness of Ti6Al4V Manufactured Using the DMLS Process

Guzanová

Ižaríková

Brezinová

et al. 2017

Metals

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show abstract

“…Heigel et al (2015) and Yang et al (2016) both used a perfect plasticity model for DED, and Heigel et al also incorporated effects from annealing due to reaching the annealing temperature for Ti6Al4V [64,70]. Vastola et al (2016) used an isotropic hardening model related to the absolute stress in the material developed during the EBM process [81]. Parry et al (2016) and Li et al (2018) additionally included effects of plastic-regime work-hardening to model SLM-based processing [73,82].…”

Section: Modeling and Simulation Of Metal-based Additive Manufacturinmentioning

confidence: 99%

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

Bandyopadhyay

Traxel

2018

Additive Manufacturing

128

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Next generation, additively-manufactured metallic parts will be designed with application-optimized geometry, composition, and functionality. Manufacturers and researchers have investigated various techniques for increasing the reliability of the metal-AM process to create these components, however, understanding and manipulating the complex phenomena that occurs within the printed component during processing remains a formidable challenge—limiting the use of these unique design capabilities. Among various approaches, thermomechanical modeling has emerged as a technique for increasing the reliability of metal-AM processes, however, most literature is specialized and challenging to interpret for users unfamiliar with numerical modeling techniques. This review article highlights fundamental modeling strategies, considerations, and results, as well as validation techniques using experimental data. A discussion of emerging research areas where simulation will enhance the metal-AM optimization process is presented, as well as a potential modeling workflow for process optimization. This review is envisioned to provide an essential framework on modeling techniques to supplement the experimental optimization process.

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“…First principles models, both simple and complex, were proposed by Patterson et al [35][36] and Fergani et al [61], all of which were demonstrated and verified using various numerical experiments and comparisons to published experimental data. Examples of computational studies that were verified using various simple part deformation experiments were those performed by Vrancken et al [62] [71] were multiscale finite element models for fast and efficient prediction of part distortion, primarily intended to inform part designers and engineers.…”

Section: Stress and Distortion Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce fulldensity metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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Controlling of residual stress in additive manufacturing of Ti6Al4V by finite element modeling

Cited by 147 publications

References 21 publications

Influence of Build Orientation, Heat Treatment, and Laser Power on the Hardness of Ti6Al4V Manufactured Using the DMLS Process

Influence of Build Orientation, Heat Treatment, and Laser Power on the Hardness of Ti6Al4V Manufactured Using the DMLS Process

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

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