Prediction of Residual Stress and Part Distortion in Selective Laser Melting

Li, C.; Liu, J. F.; Guo, Y. B.

doi:10.1016/j.procir.2016.02.058

Cited by 104 publications

(78 citation statements)

References 10 publications

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“…Stress models built using ANSYS include those models developed by Zaeh and Branner [66] and Gu and He [67]. The studies by Li et al [68,69], Parry et al [70] and Vastola et al [71] were multiscale finite element models for fast and efficient prediction of part distortion, primarily intended to inform part designers and engineers.…”

Section: Stress and Distortion Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

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Abstract:A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of the literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging and design-of-experiments), support structure optimization and overhang feature design; approximately 143 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs and potential future research directions are discussed in-depth in light of the present review.

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Section: Stress and Distortion Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

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“…Stress models built using ANSYS include those models developed by Zaeh & Branner [66] and Gu & He [67]. The studies by Li et al [68][69], Parry et al [70], and Vastola et al [71] were multiscale finite element models for fast and efficient prediction of part distortion, primarily intended to inform part designers and engineers.…”

Section: Stress and Distortion Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce fulldensity metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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“…Once the build is completed, excess powder need to be removed, and the parts fabricated must be detached from the substrate. Usually this last operation is made after a stress relieving heat treatment, performed to release the thermal stresses that arise during the L-PBF process, which otherwise could lead to deformation of the parts and to loose dimensional tolerances [12,13]. Finally, a post-process treatment like a grit blasting, also called micro-shot peening, is suggested to remove from the surface the sticky particles, which are not melt but only adhere to the surface, and to reduce the surface roughness of the parts [14].…”

Section: Introductionmentioning

confidence: 99%

Laser Powder Bed Fusion of Aluminum Alloys

Manfredi¹,

Bidulský²

2017

Acta Metall Slovaca

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The aim of this study is to analyze and to summarize the results of the processing of aluminum alloys, and in particular of the Al-Si-Mg alloys, by means of the Additive Manufacturing (AM) technique defined as Laser Powder Bed Fusion (L-PBF). This process is gaining interest worldwide thanks to the possibility of obtaining a freeform fabrication coupled with high mechanical strength and hardness related to a very fine microstructure. L-PBF is very complex from a physical point of view, due to the extremely rapid interaction between a concentrated laser source and micrometric metallic powders. This generate very fast melting and subsequent solidification on each layer and on the previously consolidated substrate. The effects of the main process variables on the microstructure and mechanical properties of the final parts are analyzed: from the starting powder properties, such as shape and powder size distribution, to the main process parameters, such as laser power, scanning speed and scanning strategy. Furthermore, some examples of applications for the AlSi10Mg alloy are illustrated.

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Prediction of Residual Stress and Part Distortion in Selective Laser Melting

Cited by 104 publications

References 10 publications

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Laser Powder Bed Fusion of Aluminum Alloys

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