Estimates of the mechanical properties of laser powder bed fusion Ti-6Al-4V parts using finite element models

Zhang, Qi; Xie, Jiawen; London, Tyler; Griffiths, David; Bhamji, Imran; Oancea, Victor

doi:10.1016/j.matdes.2019.107678

Cited by 39 publications

(17 citation statements)

References 42 publications

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“…The movement of the heat source was implemented with the use of an event series replicating exactly the movement of the scanning strategy. For more detail on this approach, please see references [36,37] where the thermal approach is fully described. Images of the scan strategy used can be seen in Fig.…”

Section: Thermal Simulationmentioning

confidence: 99%

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Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Yang

Allen

London

et al. 2019

Integr Mater Manuf Innov

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The laser powder bed fusion (LPBF) process involves using a laser beam to selectively melt metal powder with a desired shape on a substrate to create a part layer-by-layer. As an Additive Manufacturing (AM) process, laser powder bed fusion (commonly referred to as selective laser melting-SLM) offers superior design freedom over conventional manufacturing methods and enables the production of complex, lightweight geometries with applications in the aerospace, automotive, and biomedical industries. In addition to enhanced design freedom, AM technologies provide improved material utilization and allow for reduced assembly needs. However, the reliability and repeatability of additively manufactured parts is a challenge to the wide-scale adoption of the technology for safety critical parts. A critical limitation of process optimization is the prediction and control of residual stresses, distortion, and microstructure evolution. This work focuses on the development and implementation of a numerical modeling technique for the prediction of residual strains within an Inconel 625 LPBF part. The model, using the SIMULIA Additive Manufacturing Scenario App, based on the Abaqus 2018 finite element solver, was developed and analyzed as part of a submission for the NIST AM Benchmark 2018. A sequentially coupled thermo-mechanical analysis was adopted to replicate the building conditions of a single cantilever beam built at the NIST laboratories. The results of the blind study were compared to X-ray diffraction (XRD) measurements of the physical build. The predicted three-dimensional residual strain field showed a high level of accuracy and the submission described in this paper received joint first prize in the residual elastic strain category of the NIST AM Benchmark 2018. The results presented in this paper reflect only findings before the benchmark measurements were posted on the NIST website.

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Section: Thermal Simulationmentioning

confidence: 99%

“…The same step time and time points sequence were used, although a smaller time increment was used to ease convergence. Further details on this can be found in references [36,37].…”

Section: Mechanical Simulationmentioning

confidence: 99%

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Yang

Allen

London

et al. 2019

Integr Mater Manuf Innov

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“…The average surface hardness of the as-SLM sample was approximately 396.4 HV, which increased up to 455.7 and 877.6 HV for the UNSM-25C and UNSM-800C samples, corresponding to a 13.1% and 221.3%, respectively. It is well documented in the literature that the increase in hardness is due to the combination of grain refinement by Hall-Petch expression and increased dislocation density, which are the results of elasto-plastic deformation and S 2 PD took place in the top and subsurface layers [30]. The deformation usually refined the grains, which hinder further deformation and gradually diminishes with the depth of the surface layer.…”

Section: Surface Integritymentioning

confidence: 95%

Tribology of Ti-6Al-4V Alloy Manufactured by Additive Manufacturing

Amanov¹

2021

Tribology in Materials and Manufacturing - Wear, Friction and Lubrication

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In this study, the influence of ultrasonic nanocrystal surface modification (UNSM), which was applied as a post-additive manufacturing (AM), in terms of surface, tensile and tribological properties of Ti-6Al-4V alloy by selective laser melting (SLM) was investigated. Ti-6Al-4V alloy was subjected to UNSM at room and high temperatures (RT and HT). It was found that the UNSM enhanced the strength and reduced the roughness of the as-SLM sample, where both increased with increasing UNSM temperature. The UNSM bore influence on tribological properties, where the friction coefficient of the as-SLM sample reduced by about 25.8% and 305% and the wear resistance enhanced by about 41% and 246% at RT and HT, respectively. These are essentially attributed to the enhanced strength, smoothed surface and expelled pores from the surface. Based on SEM images, the damage caused by abrasive wear was the most observed in the wear track of the as-SLM sample than was caused by the highest wear rate. The UNSM temperaturedependent wear mechanisms were comprehensively investigated and elaborated based on the obtained experimental data and observed microstructural images. Indeed, a further investigation is required to improve the characteristics of as-SLM Ti-6Al-4V alloy to the wrought level due to the replacement possibility.

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“…Zhang et al [166] describes a semi-empirical model for the mechanical properties of PBF Ti-6Al-4V. The model correlates the parameters of a Ramberg-Osgood flow model to key microstructural characteristics, including the α/β phase fractions and the lath thickness.…”

Section: Models Targeting Flow Curve Predictionsmentioning

confidence: 99%

Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies Volume II – Predicting Material Performance from Material Microstructure

Nicolas¹,

Paulson²,

Messner³

2020

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This report describes the current state of modeling and simulation techniques for predicting the properties of materials fabricated with advanced manufacturing techniques, given the initial microstructure of the material. The report includes a literature survey and a gap analysis outlining and prioritizing key issues in applying these modeling and simulation techniques to nuclear reactor structural materials. The discussion covers both physics-based and data-driven modeling techniques and includes a broad range of manufacturing techniques and materials that may have future nuclear applications. This report is the second in a two-part series, with the first report covering modeling and simulation methods for predicting the initial, as-manufactured structure of advanced manufacturing materials, given a description of the process. Both reports focus on a set of manufacturing technologies likely to be applied to reactor structural components. Taken together, the two reports provide a complete summary of the current state of processing-structure-properties models for advanced manufacturing as well as a survey of applications to reactor structural materials.v

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Estimates of the mechanical properties of laser powder bed fusion Ti-6Al-4V parts using finite element models

Cited by 39 publications

References 42 publications

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Tribology of Ti-6Al-4V Alloy Manufactured by Additive Manufacturing

Survey of Modeling and Simulation Techniques for Advanced Manufacturing Technologies Volume II – Predicting Material Performance from Material Microstructure

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