Effect of post-heat treatment on residual stress and tensile strength of hybrid additive and subtractive manufacturing

Li, Pengfei; Gong, Yadong; Liang, Chunyou; Yang, Yuying; Cai, Ming

doi:10.1007/s00170-019-03705-2

Cited by 32 publications

(11 citation statements)

References 37 publications

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“…An advanced research focusing on both temperature and residual stresses induced by multi-pass of welding stainless steel (state material) was conducted with the final results showing the correlation between temperature distribution and residual stresses; thus, this research shared a similar basic concept with WAAM process [18]. Several mechanical property investigations which involved stainless steel SS316L as the feedstock in AM process were carried out and the researcher found that stainless steel SS316L possesses high mechanical values such as yield strength while maintaining a good ductility and notch impact resistance, which is suitable for AM-related processes [19][20]. Another advanced engineering research found that SS316L is suitable as feedstock in AM process as well as for the WAAM technology because the material possesses high strength, high ductility as well as excellent corrosion resistance [21][22].…”

Section: Introductionmentioning

confidence: 88%

Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification

Prajadhiana¹,

Manurung²,

Bauer³

et al. 2021

JAEDS

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This paper deals with a principal development of virtual manufacturing (VM) procedure to predict substrate distortion induced by Wire Arc Additive Manufacturing (WAAM) process. In this procedure, a hollow shape is designed in a thin-walled form made of stainless steel. The procedure starts with geometrical modelling of WAAM component consisting of twenty-five deposited layers with austenitic stainless-steel wire SS316L as feedstock and SS304 as substrate material. The hollow shape is modelled based on simplified rectangular mesh geometry with identical specimen dimensions during the experiment. Material model to be defined can be retrieved directly from a database or by conducting a basic experiment to obtain the evolution of material composition, characterized using Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray (EDX) analysis, and generated using advanced modelling software JMATPRO for creating new properties including the flow curves. Further, a coupled thermomechanical solution is adopted, including phase-change phenomena defined in latent heat, whereby temperature history due to successive layer deposition is simulated by coupling the heat transfer and mechanical analysis. Transient thermal distribution is calibrated from an experiment obtained from thermocouple analysis at two reference measurement locations. New heat transfer coefficients are to be adjusted to reflect actual temperature change. As the following procedure prior to simulation execution, a sensitivity analysis was conducted to find the optimal number of elements or mesh size towards temperature distribution. The last procedure executes the thermomechanical numerical simulation and analysis the post-processing results. Based on all aspects in VM procedures and boundary conditions, WAAM distortion is verified using a robotic welding system equipped with a pulsed power source. The experimental substrate distortion is measured at various points before and after the process. It can be concluded based on the adjusted model and experimental verification that using nonlinear numerical computation, the prediction of substrate distortion with evolved material property of component yields far better result which has the relative error less than 11% in a comparison to database material which has 22%, almost doubled the inaccuracy.

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Section: Introductionmentioning

confidence: 88%

Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification

Prajadhiana¹,

Manurung²,

Bauer³

et al. 2021

JAEDS

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“…Heat treatment can alter the microstructure of metals, improving their ductility and strength. Pengfei et al [ 81 ] investigated the effect of post-heat treatment on the residual stress of 316 L stainless steel fabricated using the DLD process. The results showed that the tensile residual stress of the specimen decreased significantly when a heat treatment was applied at 400 °C for 2 h. The tensile residual stress was reduced to 356.29 MPa (53.7% reduction) for samples that were heat treated at 400 °C for 2 h compared to 769.27 MPa for untreated samples.…”

Section: Methods For Mitigating Residual Stressmentioning

confidence: 99%

A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

Bastola,

Jahan,

Rangasamy

et al. 2023

Micromachines

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Metal additive manufacturing (AM) is capable of producing complex parts, using a wide range of functional metals that are otherwise very difficult to make and involve multiple manufacturing processes. However, because of the involvement of thermal energy in the fabrication of metallic AM parts, residual stress remains one of the major concerns in metal AM. This residual stress has negative effects on part quality, dimensional accuracy, and part performance. This study aims to carry out a comprehensive review and analysis of different aspects of residual stress, including the causes and mechanisms behind the generation of residual stress during metal AM, the state-of-the-art measurement techniques for measuring residual stress, various factors influencing residual stress, its effect on part quality and performance, and ways of minimizing or overcoming residual stress in metal AM parts. Residual stress formation mechanisms vary, based on the layer-by-layer deposition mechanism of the 3D printing process. For example, the residual stress formation for wire-arc additive manufacturing is different from that of selective laser sintering, direct energy deposition, and powder bed fusion processes. Residual stress formation mechanisms also vary based on the scale (i.e., macro, micro, etc.) at which the printing is performed. In addition, there are correlations between printing parameters and the formation of residual stress. For example, the printing direction, layer thickness, internal structure, etc., influence both the formation mechanism and quantitative values of residual stress. The major effect residual stress has on the quality of a printed part is in the distortion of the part. In addition, the dimensional accuracy, surface finish, and fatigue performance of printed parts are influenced by residual stress. This review paper provides a qualitative and quantitative analysis of the formation, distribution, and evolution of residual stress for different metal AM processes. This paper also discusses and analyzes both in situ and ex situ measurement techniques for measuring residual stress. Microstructural evolution and its effect on the formation of residual stress are analyzed. Various pre- and post-processing techniques used to countermeasure residual stress are discussed in detail. Finally, this study aims to present both a qualitative and quantitative analysis of the existing data and techniques in the literature related to residual stress, as well as to provide a critical analysis and guidelines for future research directions, to prevent or overcome residual stress formation in metal AM processes.

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“…At 5000×, the dimple network is noticed along with void coalescence ( Figure 14 b). According to Pengfe Li et al [ 24 ], the dimple structure denotes ductile fracture and if it is in excess, it may lead to reduction in tensile strength. At 2000× magnification along with dimple structure, flat regions were observed suggesting mixed mode of fracture ( Figure 14 c).…”

Section: Tensile Test Digital Image Correlation Fractography Anmentioning

confidence: 99%

Digital Image Correlation of Tensile Properties for Monel 400/SS 316L Dissimilar Metal Welding Joints

et al. 2021

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Dissimilar metal weld joints of Monel 400 and Stainless Steel 316L stainless steel were carried out using Gas Tungsten Arc Welding (GTAW). Conventional annealing and cryogenic treatment were performed on the welded joints. Weld joints of this combination of materials have enormous potential applications in power industry and the available related literature is limited. In the present study, the tensile properties of heat treated (HT), cryotreated (CT), and untreated (UT) specimens were studied. The engineering stress and strain were determined experimentally as per Standard Test Methods for Tension Testing of Metallic Materials (ASTM E8). The strain distribution was evaluated at different zones of weld joint was evaluated using Digital Image Correlation (DIC). Significant difference was noticed between the zones. Weld zone of all samples had less local stress and strain and SS 316L heat affected zone (HAZ) zone had more local stress and strain when compared to other zones. The local strain distribution along distance from weld center line and local stress-strain curves of different zones are also predicted. Scanning Electron Microscopy was used to analyze the fracture behavior of welded samples for HT, CT, and UT specimens.

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Effect of post-heat treatment on residual stress and tensile strength of hybrid additive and subtractive manufacturing

Cited by 32 publications

References 37 publications

Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification

Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification

A Review of the Residual Stress Generation in Metal Additive Manufacturing: Analysis of Cause, Measurement, Effects, and Prevention

Digital Image Correlation of Tensile Properties for Monel 400/SS 316L Dissimilar Metal Welding Joints

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