Numerical study of the effect of progressive solidification on residual stress in single-bead-on-plate additive manufacturing

Ha, Kyeongsik; Kim, Tae‐Hwan; Baek, Gyeong Yun; Jeon, Jong Bae; Shim, Do-Sik; Moon, Young Hoon; Lee, Wookjin

doi:10.1016/j.addma.2020.101245

Cited by 13 publications

(10 citation statements)

References 19 publications

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“…A similar reduced‐order modeling strategy has also been adopted in a study for simulation of the single‐bead DED process. [ 117 ] By simplifying mechanical model, Ding et al [ 118 ] proposed an efficient engineering FEM model for fast simulation of the large‐scale WAAM process, and the result shows that this method has good accuracy and time saving. Montevecchi et al [ 98 ] simulated the distortions and RS evolution in the AM parts using the FEM and mesh coarsening method, which could reduce the computational cost by significant reduction of the number of elements required.…”

Section: Modeling and Simulation Of Residual Stressmentioning

confidence: 99%

Evolution, Control, and Mitigation of Residual Stresses in Additively Manufactured Metallic Materials: A Review

Liu,

Shi,

Wang

2023

Adv Eng Mater

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Powder bed fusion (PBF) and directed energy deposition (DED) are the two major types of metal additive manufacturing (AM) processes, in which significant residual stresses could be generated in the as‐deposited materials and in turn affect part quality and performance. Therefore, how to control and mitigate residual stress has been a most pressing challenge for metal AM. In this paper, we systematically review the significant efforts made in literature to address this challenge for both PBF and DED processes. The extensive survey covers the formation of residual stress in AM, influence of various AM process parameters, modeling techniques for predicting residual stresses, and post and in‐situ treatments for mitigating unfavorable residual stress distributions. More importantly, a critical analysis is provided to discuss the research gaps and opportunities, such that more exciting research will be stimulated to address the outstanding issues in this area, and improve the quality and service life of AM produced components. As a result, once being better equipped with residual stress control knowledge and tools, the industry will be more confident in adopting metal AM techniques.This article is protected by copyright. All rights reserved.

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Section: Modeling and Simulation Of Residual Stressmentioning

confidence: 99%

Evolution, Control, and Mitigation of Residual Stresses in Additively Manufactured Metallic Materials: A Review

Liu,

Shi,

Wang

2023

Adv Eng Mater

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“…It can be greatly influenced by the deposited materials, laser power, laser scanning speed, laser beam radius, and structure of the substrate. In the past years, the effect of the DED AM parameters on the residual stress has been given more attention [10][11][12][13][14][15][16]. Ha et al [10] studied the effects of the temperature and progressive solidification on residual stress and showed that distortion of the solid-liquid interface led to a decrease in the residual stress.…”

Section: Introductionmentioning

confidence: 99%

“…In the past years, the effect of the DED AM parameters on the residual stress has been given more attention [10][11][12][13][14][15][16]. Ha et al [10] studied the effects of the temperature and progressive solidification on residual stress and showed that distortion of the solid-liquid interface led to a decrease in the residual stress. Mukherjee et al [11] found that the residual stress in the laser additive manufacturing products can be greatly decreased by reducing the layer thickness.…”

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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“…There is bound to be an obvious temperature gradient distribution in each part of the formed part. The temperature gradient is closely related to the microstructure and mechanical properties of the material: on the one hand, an excessive temperature gradient reduces the uniformity of the grain size in the thickness direction of the material and increases the anisotropy of the material [9]. On the other hand, when the material undergoes cold plastic deformation, uneven deformation occurs between grains or between subgrains within grains, which induces microscopic internal stress.…”

Section: Introductionmentioning

confidence: 99%

Liquid Metal-assisted In-situ Control of Temperature Field for Additive Manufacturing of Titanium Alloys

Zhang¹,

Xia²,

Hu³

2022

Preprint

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How to effectively suppress thermal cracks in the metal laser additive manufacturing process is still one of the key issues to be solved in the field of laser additive manufacturing. Metal tin, with wide liquid phase working temperature range, high boiling point, low viscosity, high thermal conductivity and excellent electrical conductivity. The use of tin as an auxiliary thermal management material in the metal additive manufacturing process is expected to achieve effective regulation of the temperature field and stress field of the formed part, thereby inhibiting the initiation of cracks and obtaining formed parts with the target grain structure and high reliability. This paper presented a novel liquid metal-assisted laser additive manufacturing method (LMAAM). A numerical model for the laser additive manufacturing of tin-assisted titanium alloys was established. The differences of the flow field, temperature field and stress field of the formed parts with tin and without tin were compared and analyzed. The influence of the interaction position between the tin liquid level and the forming part on the temperature field and stress field of the forming part was deeply studied. The laser additive manufacturing experiment of tin-assisted titanium alloy was carried out, and the experimental results were basically consistent with the simulation results, which verified the validity of the model. LMAAM technology has proven to be an effective method for additive manufacturing of highly reliable formed parts.

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Numerical study of the effect of progressive solidification on residual stress in single-bead-on-plate additive manufacturing

Cited by 13 publications

References 19 publications

Evolution, Control, and Mitigation of Residual Stresses in Additively Manufactured Metallic Materials: A Review

Evolution, Control, and Mitigation of Residual Stresses in Additively Manufactured Metallic Materials: A Review

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

Liquid Metal-assisted In-situ Control of Temperature Field for Additive Manufacturing of Titanium Alloys

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