Numerical studies of residual states and scaling effects in laser-directed energy deposition additive manufacturing

Zhang, Zhao; Ge, P.; Yao, X.X.; Li, T.; Liu, Wei Wei

doi:10.1007/s00170-020-05300-2

Cited by 18 publications

(7 citation statements)

References 30 publications

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“…In order to reduce residual stresses in the fabricated part by DED processes, various experimental and analytical approaches were performed [97,203,204,223,224,[271][272][273][274][275][276][277][278][279][280][281][282][283][284][285][286]. Recently, researches on thermo-mechanical analyses steadily increased to predict the desired deposition method through the control of heat transfer characteristics and the reduction of residual stress evolution, as shown in Table 13.…”

Section: Thermo-mechanical Analysismentioning

confidence: 99%

“…In addition, they estimated the relationship between non-dimensional deposition parameters and the normalized dilution [278]. In order to obtain proper designs of fabricated parts by DED processes, the influence of geometry parameters, including the bead length, the up-lift height, the wall height, the wall thickness, the radius, etc., on residual stress and deflection distributions was examined using thermo-mechanical analyses for DED processes [203,277,280]. Zhang et al [280] studied the effects of radius and height of a circular thin wall part on residual distortion distributions for a LAM-DED process.…”

Section: Thermo-mechanical Analysismentioning

confidence: 99%

See 1 more Smart Citation

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

373

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Metal additive manufacturing technologies, such as powder bed fusion process, directed energy deposition (DED) process, sheet lamination process, etc., are one of promising flexible manufacturing technologies due to direct fabrication characteristics of a metallic freeform with a three-dimensional shape from computer aided design data. DED processes can create an arbitrary shape on even and uneven substrates through line-by-line deposition of a metallic material. Theses DED processes can easily fabricate a heterogeneous material with desired properties and characteristics via successive and simultaneous depositions of different materials. In addition, a hybrid process combining DED with different manufacturing processes can be conveniently developed. Hence, researches on the DED processes have been steadily increased in recent years. This paper reviewed recent research trends of DED processes and their applications. Principles, key technologies and the state-of-the art related to the development of process and system, the optimization of deposition conditions and the application of DED process were discussed. Finally, future research issues and opportunities of the DED process were identified.

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Section: Thermo-mechanical Analysismentioning

confidence: 99%

Section: Thermo-mechanical Analysismentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

373

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“…The increase of the distortion comes from the increased accumulated heat in the case for the plate-column PnC. According to [59,64,65], the maximum temperature in AM can be accumulated to be higher with the increase of layers. The increase of the accumulated heat can lead to the increase of the thermal distortion according to [65].…”

Section: Printing Accuracy and The Re-construction Of Pncs Modelsmentioning

confidence: 99%

The influence of printing accuracy on the performance of additively manufactured AlSi10Mg phononic crystals

Wang¹,

Guo²,

Zhang³

2022

Phys. Scr.

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The printing accuracy is one of the key factors affecting the final additively manufactured structures. As metamaterials for wave controlling, the printing accuracy caused in additive manufacturing can affect the band gap structures and the wave transmissions in phononic crystals (PnCs). Selective laser melting (SLM) was used to fabricate the designed PnCs. AlSi10Mg was used as the material for the fabrication. The distorted geometry of the additively manufactured PnCs by selective laser melting (SLM) was experimentally measured and then was re-built as finite element model. The band gap structures and the wave transmissions were calculated based on finite element method for the comparison of the structural performances of the theoretically designed and fabricated PnCs. Result indicated that the fabricated PnCs were thermally distorted from 0.298 mm to 1.664 mm depending on the designed geometries. The thermal distortion can lead to a deviation of central frequency in the range of -6.2%~3.7% in comparison with the theoretical design. Compared with the theoretical design, the band gap widths of the distorted PnCs vary from -7.4% to 5.6% due to the frequencies change of the eigenmodes at the upper and lower band edges which are directly affected by the thermal distortion. The further analysis shows that the change of the band structures of the distorted PnCs is due to the increase of the inertia moment of the distorted PnCs caused by the printing accuracy.

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“…It is necessary to put forward a new study on the effect of the substrate structure and the constraints on residual stress. In this paper, a sequentially coupled thermomechanical model [26,27] was utilized to simulate the residual stresses in DED AM products with different substrate structures and constraints. Then an experiment was also developed to validate the simulation results.…”

Section: Introductionmentioning

confidence: 99%

Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products

Jing

Zhang

et al. 2022

Metals

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A new method of controlling the residual stress in laser directed energy deposition additive manufacturing (DED AM) products proposed based on constraints used in manufacturing and the substrate design. The simulation results of the residual stress, which were validated with the experimental measured data, showed that weaker constraints on the substrate could greatly decrease the residual stress in the laser DED AM products. In addition, by designing local reduced thickness regions into the substrate, such as long strip holes or support legs, the residual stress in DED AM products could be further decreased. In this study, when long strip holes were designed in the substrate, the tensile residual stress was decreased by 28%. An even smaller amount of residual stress was achieved when the design structure was changed to support legs. The tensile residual stress decreased by more than 30%. The fewer support legs, the smaller the residual stress. The residual stress in DED AM products could be well-controlled by design, while the stiffness can be weakened with fewer constraints.

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Numerical studies of residual states and scaling effects in laser-directed energy deposition additive manufacturing

Cited by 18 publications

References 30 publications

Directed Energy Deposition (DED) Process: State of the Art

Directed Energy Deposition (DED) Process: State of the Art

The influence of printing accuracy on the performance of additively manufactured AlSi10Mg phononic crystals

Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products

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