Residual stress analysis through numerical simulation in powder bed additive manufacturing using the representative volume approach

Homami, Rasool Mokhtari; Ojo, Olanrewaju

doi:10.1007/s00170-023-12634-0

Cited by 2 publications

(1 citation statement)

References 42 publications

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“…In the past, most of the stress field simulations in additive manufacturing focused on residual stress simulations of single-bead and multi-layer without overlap [ 23 , 24 , 25 , 26 , 27 , 28 ]. The influence of overlap on temperature and stress fields is rarely considered.…”

Section: Introductionmentioning

confidence: 99%

Simulation Study on Temperature and Stress Fields in Mg-Gd-Y-Zn-Zr Alloy during CMT Additive Manufacturing Process

Zhao,

et al. 2024

Materials

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A new heat source combination, consisting of a uniform body heat source and a tilted double ellipsoidal heat source, has been developed for cold metal transfer (CMT) wire-arc additive manufacturing of Mg-Gd-Y-Zn-Zr alloy. Simulations were conducted to analyze the temperature field and stress distribution during the process. The optimal combination of feeding speed and welding speed was found to be 8 m/min and 8 mm/s, respectively, resulting in the lowest thermal accumulation and residual stress. Z-axis residual stress was identified as the main component of residual stress. Electron Backscatter Diffraction (EBSD) testing showed weak texture strength, and Kernel Average Misorientation (KAM) analysis revealed that the 1st layer had the highest residual stress, while the 11th layer had higher residual stress than the 6th layer. Microhardness in the 1st, 11th, and 6th layers varies due to residual stress impacts on dislocation density. Higher residual stress increases dislocation density, raising microhardness in components. The experimental results were highly consistent with the simulated results.

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Section: Introductionmentioning

confidence: 99%

Simulation Study on Temperature and Stress Fields in Mg-Gd-Y-Zn-Zr Alloy during CMT Additive Manufacturing Process

Zhao,

et al. 2024

Materials

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Study on the residual stress of simple cubic lattice structure produced by selective laser melting

Zhao,

Yang,

Zhang

et al. 2024

Jnl of Sandwich Structures & Materials

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Lattice structures become the focus for scholars to research due to its unique lightweight, high impact resistance and ideal noise reduction. Selective laser melting has become a very effective and convenient method for preparing lattice structures of excellent quality. However, it is imperative to acknowledge that rapid heating and cooling processes inherent to the method can generate excessive residual stresses within the lattice structures, thereby significantly compromising their mechanical properties. To address this issue, the present study seeks to elucidate the patterns and characteristics of distribution of residual stresses and deformations within simple cubic lattice structures, employing a combination of experimental techniques and finite element analysis. The fabrication of these simple cubic lattice structures is accomplished through selective laser melting. The investigation encompasses both two methods, involving X-ray measurements at discrete points on the structure, and finite element simulations to depict the overall stress distribution. The results show that the residual stress and deformation are more likely concentrated on the initial surface to be processed, and residual stress on the substrates is bigger than that on bars. Specifically, the biggest stress concentrates on the Z-bars, up to 1393 MPa. However, in terms of the overall state of stress distribution in the structure, the residual stress on the substrate is slightly higher than that on the lattice structure.

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Residual stress analysis through numerical simulation in powder bed additive manufacturing using the representative volume approach

Cited by 2 publications

References 42 publications

Simulation Study on Temperature and Stress Fields in Mg-Gd-Y-Zn-Zr Alloy during CMT Additive Manufacturing Process

Simulation Study on Temperature and Stress Fields in Mg-Gd-Y-Zn-Zr Alloy during CMT Additive Manufacturing Process

Study on the residual stress of simple cubic lattice structure produced by selective laser melting

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