Experimental validation of finite element modeling for laser powder bed fusion deformation

Dunbar, Alexander J.; Denlinger, Erik R.; Gouge, Michael; Michaleris, P.

doi:10.1016/j.addma.2016.08.003

Cited by 73 publications

(41 citation statements)

References 25 publications

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“…FE modelling has been mainly employed to assess the influence of process parameters [30,38,46] and to evaluate distortions and residual stresses [9,13,16,23,34]. In this sense, thermal modelling, apart from being an input for the mechanical analysis, is fundamental to characterise the melt pool and the microstructure in an AM process [20,25,33,41] and also guides the selection of the printing process parameters in engineering design [26,32,44].…”

Section: Introductionmentioning

confidence: 99%

“…Computational complexity is one of the reasons why most experimental studies with powder-bed technologies consider short single-part builds of less than 15 layers and 1 cm 3 volume [14,22,30,36]. Fewer works attempt at higher deposition volumes [15,34], longer processes [16], or multiple parts [19,34], but barely any of these experimental builds approach the limits of current machines.…”

Section: Introductionmentioning

confidence: 99%

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Numerical modelling and experimental validation in Selective Laser Melting

Chiumenti

Neiva

Salsi

et al. 2017

Additive Manufacturing

113

111

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In this work a finite-element framework for the numerical simulation of the heat transfer analysis of additive manufacturing processes by powder-bed technologies, such as Selective Laser Melting, is presented. These kind of technologies allow for a layer-by-layer metal deposition process to cost-effectively create, directly from a CAD model, complex functional parts such as turbine blades, fuel injectors, heat exchangers, medical implants, among others. The numerical model proposed accounts for different heat dissipation mechanisms through the surrounding environment and is supplemented by a finite-element activation strategy, based on the born-dead elements technique, to follow the growth of the geometry driven by the metal deposition process, in such a way that the same scanning pattern sent to the numerical control system of the AM machine is used. An experimental campaign has been carried out at the Monash Centre for Additive Manufacturing using an EOSINT-M280 machine where it was possible to fabricate different benchmark geometries, as well as to record the temperature measurements at different thermocouple locations. The experiment consisted in the simultaneous printing of two walls with a total deposition volume of 107 cm3 in 992 layers and about 33,500 s build time. A large number of numerical simulations have been carried out to calibrate the thermal FE framework in terms of the thermophysical properties of both solid and powder materials and suitable boundary conditions. Furthermore, the large size of the experiment motivated the investigation of two different model reduction strategies: exclusion of the powder-bed from the computational domain and simplified scanning strategies. All these methods are analysed in terms of accuracy, computational effort and suitable applications.Peer ReviewedPostprint (author's final draft

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical modelling and experimental validation in Selective Laser Melting

Chiumenti

Neiva

Salsi

et al. 2017

Additive Manufacturing

113

111

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“…A variety of methods are capable of measuring the thermal history during AM processes. Thermocouples have been used to measure the temperature at select points on parts during a variety of AM processes and those measurements have been used to validate process models [4], [5] and to investigate different processing strategies [6]. However, thermocouples have limited application in AM research because they must be attached to the substrate before the process begins, and can only measure temperature near the melt pool if the process is paused to allow additional thermocouples to be attached [4].…”

Section: Introductionmentioning

confidence: 99%

Measurement of the Melt Pool Length During Single Scan Tracks in a Commercial Laser Powder Bed Fusion Process

Heigel

Lane

2018

Journal of Manufacturing Science and Engineering

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This work presents high-speed thermographic measurements of the melt pool length during single track laser scans on nickel alloy 625 substrates. Scans are made using a commercial laser powder bed fusion (PBF) machine while measurements of the radiation from the surface are made using a high speed (1800 frames per second) infrared camera. The melt pool length measurement is based on the detection of the liquidus–solidus transition that is evident in the temperature profile. Seven different combinations of programmed laser power (49–195 W) and scan speed (200–800 mm/s) are investigated, and numerous replications using a variety of scan lengths (4–12 mm) are performed. Results show that the melt pool length reaches steady-state within 2 mm of the start of each scan. Melt pool length increases with laser power, but its relationship with scan speed is less obvious because there is no significant difference between cases performed at the highest laser power of 195 W. Although keyholing appears to affect the anticipated trends in melt pool length, further research is required.

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“…Therefore, this section discusses and summarizes the efforts that have been made to simulate and predict the interaction of SLM parameters and components quality. FEM is widely applied to examine the impact of processes parameters to evaluate melt pool dynamics, induced residual stresses and microstructure alteration [ 111 , 112 , 113 , 114 ]. Thermal simulation, which is mainly fed as an input for the mechanical analysis, is also applied to assess the melt pool geometry and stability and microstructure variation along the build direction [ 115 , 116 , 117 ].…”

Section: Numerical Simulation Of Slmmentioning

confidence: 99%

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

et al. 2020

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Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.

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Experimental validation of finite element modeling for laser powder bed fusion deformation

Cited by 73 publications

References 25 publications

Numerical modelling and experimental validation in Selective Laser Melting

Numerical modelling and experimental validation in Selective Laser Melting

Measurement of the Melt Pool Length During Single Scan Tracks in a Commercial Laser Powder Bed Fusion Process

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

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