Simulation of additive manufacturing using coupled constitutive and microstructure models

Lindgren, Lars‐Erik; Lundbäck, Andreas; Fisk, Martin; Pederson, Robert; Andersson, Joel

doi:10.1016/j.addma.2016.05.005

Cited by 100 publications

(84 citation statements)

References 76 publications

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“…They found that the maximum residual stresses exist at the end of the first track and last track, which was also confirmed by experimental results. In order to consider the microstructure effect, coupled constitutive and microstructure models are part of the simulation model of Lindgren et al [14], in which precipitation hardening and phase change are also included.…”

Section: Introductionmentioning

confidence: 99%

Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Zhang

Guillemot

Bernacki

et al. 2018

Computer Methods in Applied Mechanics and Engineering

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A 3D finite element model is developed to study heat exchange during metal selective laser melting (SLM). The approach is conducted on the scale of the part to be formed, using a level set framework to track the interface between the constructed workpiece and non-melted powder, and interface between the gas domain and the successive powder bed layers. In order to keep sustainable the computational efficiency, the powder bed deposition and the energy input are simplified by the scale of an entire layer or fractions of each layer. Layer fractions are identified directly from a description of the global laser scan plan of the part to be built. Each fraction is heated during a time interval corresponding to the exposure time to the laser beam, and then cooled down during a time interval equal to the scan time for the considered layer fraction. The global heat transfer through the part under additive construction and through the powder material non-exposed to the laser beam is simulated. To reduce the computational cost, a refining and de-refining mesh adaptation is carried out with a conform mesh strategy. Mesh sensitivity tests and validation of energy conservation are discussed. The proposed model is able to predict the temperature distribution and evolution in the constructed workpiece and non-melted powder during the SLM process at the macroscale, for parts of complex geometry.Application is shown for a nickel based alloy (IN718), but the numerical model can be easily extended to other materials by using their data sets.

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Section: Introductionmentioning

confidence: 99%

Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Zhang

Guillemot

Bernacki

et al. 2018

Computer Methods in Applied Mechanics and Engineering

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show abstract

“…Maintenance tasks can be highly sophisticated and unpredictable and may require customized, low-quantity parts to be dispatched to remote locations. [148] Copyright 2016, Elsevier. There may also be high transportation costs to dispatch the parts and unpredictable equipment availability if they need to be produced.…”

Section: Benefits Of Am Technology In Aerospace and Defense Applicationsmentioning

confidence: 99%

Laser‐Based Additive Manufacturing Technologies for Aerospace Applications

2019

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Additive manufacturing (AM) is a transformative technology that has rapidly grown over the past decade. AM processes build parts layer by layer and have found applications in the aerospace, biomedical, and automotive fields. The technology holds particular promise for the aerospace industry due to the reduced process time, weight savings of parts, and opportunities for new material development. Herein, a review of laser-based AM processes, existing AM systems, and aerospace parts being fabricated is presented. It further explores the material properties and microstructure of printed samples with both powder bed fusion and direct energy deposition processes. The benefits and challenges associated with the widespread use of the technology are discussed with emphases on the aerospace sector. Finally, the steps required for parts produced by AM processes to become certified for use in aerospace applications are presented.

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“…Figure 3B provides an indication of the current state of modeling additive manufacturing-related phenomena on several different length scales. Microstructural and mesoscale modeling has been investigated to model phenomena such as grain growth and phase formations [49,50], and integrated approaches have been made to combine different length scale simulations [51,52]. The more commonly employed simulations for end-users, however, are on the part level i.e.…”

Section: Metallic Am – Towards Processing Simulationmentioning

confidence: 99%

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

Bandyopadhyay

Traxel

2018

Additive Manufacturing

128

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Next generation, additively-manufactured metallic parts will be designed with application-optimized geometry, composition, and functionality. Manufacturers and researchers have investigated various techniques for increasing the reliability of the metal-AM process to create these components, however, understanding and manipulating the complex phenomena that occurs within the printed component during processing remains a formidable challenge—limiting the use of these unique design capabilities. Among various approaches, thermomechanical modeling has emerged as a technique for increasing the reliability of metal-AM processes, however, most literature is specialized and challenging to interpret for users unfamiliar with numerical modeling techniques. This review article highlights fundamental modeling strategies, considerations, and results, as well as validation techniques using experimental data. A discussion of emerging research areas where simulation will enhance the metal-AM optimization process is presented, as well as a potential modeling workflow for process optimization. This review is envisioned to provide an essential framework on modeling techniques to supplement the experimental optimization process.

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Simulation of additive manufacturing using coupled constitutive and microstructure models

Cited by 100 publications

References 76 publications

Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Macroscopic thermal finite element modeling of additive metal manufacturing by selective laser melting process

Laser‐Based Additive Manufacturing Technologies for Aerospace Applications

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

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