Investigation of effects of different moving heat source scanning patterns on thermo-mechanical behavior in direct energy deposition manufacturing

Mirazimzadeh, Seyedeh Elnaz; Pazireh, Syamak; Urbanic, Jill; Hedrick, R.

doi:10.1007/s00170-022-08970-2

Cited by 12 publications

(4 citation statements)

References 14 publications

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“…In the simulation and computation of SLM additive manufacturing, a common approach is to employ a heat source model to simulate the material's absorption of energy instead of directly modeling the laser. One frequently used model for the laser heat source is the Moving Heat Source (MHS) model [32]. This method is based on the heat conduction equation for numerical computation.…”

Section: Heat Source Modelingmentioning

confidence: 99%

Simulation Study on the Energy Utilization Efficiency of a Turbine Impeller Based on a Selective Laser Melting Process

Guo,

Wang,

Wang

et al. 2023

Applied Sciences

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In this paper, a simulation model for Selective Laser Melting (SLM) technology is established to simulate the additive manufacturing process of a turbine impeller for an aerospace engine. By utilizing the simulation model, variations in laser power and scanning speed are employed to obtain simulated results of thermal deformation for the turbine impeller under different laser power and scanning speed conditions. The results indicate that the thermal deformation of the component increases with the augmentation of laser power, decreases with the escalation of scanning speed, and eventually stabilizes. Based on the relationship between thermal deformation and energy, the energy utilization efficiency of the SLM process under different conditions is calculated. The findings demonstrate that, within a certain range of power, the synergistic effect of laser power and scanning speed allows for an increase in energy utilization efficiency and a reduction in processing time while ensuring the mechanical performance of the formed parts. Consequently, this approach proves effective in lowering production costs for complex components based on SLM technology.

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Section: Heat Source Modelingmentioning

confidence: 99%

Simulation Study on the Energy Utilization Efficiency of a Turbine Impeller Based on a Selective Laser Melting Process

Guo,

Wang,

Wang

et al. 2023

Applied Sciences

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“…In addition to the two categories of influences, time interval, and part size, the scanning strategy is also a critical factor in the thermal history. Mirazimzadeh et al [26] conducted a comprehensive study of the thermal history variations and residual stresses in three geometries on the Fluent-ANSYS platform, exploring one-way, zig-zag, spiral, and raster-angled pattern scans for various component configurations. Their results elucidated the different responses of different scanning methods for parts with different wall thicknesses.…”

Section: Introductionmentioning

confidence: 99%

The thermal history of the directed energy deposition process monitored by pyrometer and camera

Li,

Liu,

Zhang

et al. 2024

Meas. Sci. Technol.

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In the process of directed energy deposition (DED), the local thermal history of a component can change significantly owing to its complex heat transfer characteristics. The main objective of this study is to elucidate the distribution of the thermal history of a static scroll plate by monitoring its manufacturing process through a pyrometer and camera and to provide insights into the factors affecting the variation of its thermal history from the point of view of the part shape and scanning strategy. The melt pool area and temperature were extracted using a camera and pyrometer as the thermal features under study, and the thermal features were mapped in three dimensions. This mapping strategy provides a comprehensive visualization of the distribution of thermal features in parts with equal and variable cross-section structures. In the case of an equal cross-section structure, three factors, printing time, scan vector length, and probability density, are selected to analyze the main factors affecting the distribution of thermal features. In the case of the variable cross-section structure, the effects of the layer printing time, cumulative layer printing time, and probability density on the distribution of thermal features were analyzed. By calculating the correlation between the thermal features of the monitored signals and the factors mentioned above, it was found that the factors affecting the thermal distribution of the parts vary in different structures. In equal cross-section structures, the probability density plays a pivotal role, while in variable cross-section structures, the cumulative layer printing time has the most significant influence on the thermal distribution. The above studies have provided a better understanding of the thermal processes of DED technology, paving the way for the control and optimization of DED manufacturing.

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“…They investigated the meander pattern, the spiral pattern and the newly developed S pattern and concluded that the S pattern leads to a more homogeneous temperature distribution, showing beneficial effects on the microstructure, porosity, and residual stress formation. However, Mirazimzadeh et al showed that there is coupling between the tool path and the part geometry; consequently, a solution for one configuration cannot be assumed to be transferrable to another configuration [17]. The previous studies focused on prediction of residual stress in simple and straightforward geometrical parts.…”

Section: Introductionmentioning

confidence: 99%

Exploring computational techniques for simulating residual stresses for thin wall multi-joint hexagon configurations for a laser directed energy deposition process

Mohajernia

Urbanic

2023

Int J Adv Manuf Technol

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Laser cladding is a directed energy deposition process, and can lead to high residual stresses, which can compromise the quality of the specimen. As a result, it is crucial to accurately predict and investigate the residual stress distribution in cladded parts and understand the mechanism of formation. In this study a thermo-mechanical metallurgical simulation model of the laser cladding process was developed for three different path strategies with respect to the deposition sequence and direction for a thin wall hexagon with inner junctions to investigate the formation of residual stress. The study was performed for single and multilayer scenarios. Two types of computational techniques, the detailed transient approach and the imposed thermal cycle approach, was performed and comparisons conducted. Consistent results were observed when comparing the resultant stress patterns for the single layer; subsequently, the imposed thermal cycle method was applied for the five layer models. A preheat scenario is explored. This reduced the computational cost significantly, but the stress patterns were not similar. This indicates that building up worn regions at the top of a thin walled component, such as a roll die, needs to be investigated further as unique issues have been highlighted. The differences between the implemented computational techniques are described as well as the advantages and disadvantages of each. Knowledge obtained from these case studies provides a foundation for efficient and rapid optimization of laser cladding processes, with the aim of minimizing residual stress in both simple and complex laser cladding structures.

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Investigation of effects of different moving heat source scanning patterns on thermo-mechanical behavior in direct energy deposition manufacturing

Cited by 12 publications

References 14 publications

Simulation Study on the Energy Utilization Efficiency of a Turbine Impeller Based on a Selective Laser Melting Process

Simulation Study on the Energy Utilization Efficiency of a Turbine Impeller Based on a Selective Laser Melting Process

The thermal history of the directed energy deposition process monitored by pyrometer and camera

Exploring computational techniques for simulating residual stresses for thin wall multi-joint hexagon configurations for a laser directed energy deposition process

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