Two-dimensional simulation of grain structure growth within selective laser melted AA-2024

López-Botello, Omar; Martinez-Hernandez, Uriel; Ramirez, J. E.; Pinna, C.; Mumtaz, Kamran

doi:10.1016/j.matdes.2016.10.031

Cited by 106 publications

(31 citation statements)

References 26 publications

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“…Lopez-Botelle et al studied the grain growth behavior of PBF-LB/M-manufactured EN AW-2024 using low processing speeds resulting in a predictive model for the estimation of melt pool size, gradient development and average grain size [20].…”

Section: Mechanical Propertiesmentioning

confidence: 99%

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Rasch¹,

Heberle

Dechet³

et al. 2019

Materials

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Powder Bed Fusion with Laser Beam of Metals (PBF-LB/M) is one of the fastest growing technology branches. More and more metallic alloys are being qualified, but processing of aluminum wrought alloys without cracks and defects is still challenging. It has already been shown that small parts with low residual porosity can be produced. However, suffering from microscopic hot cracks, the fracture behavior has been rather brittle. In this paper different combinations of temperature gradients and solidification rates are used to achieve specific solidification conditions in order to influence the resulting microstructure, as well as internal stresses. By this approach it could be shown that EN AW-2024, an aluminum-copper wrought alloy, is processable via PBF-LB/M fully dense and crack-free with outstanding material properties, exceeding those reported for commonly manufactured EN AW-2024 after T4 heat treatment.

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Section: Mechanical Propertiesmentioning

confidence: 99%

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Rasch¹,

Heberle

Dechet³

et al. 2019

Materials

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“…Previous work on additive manufacturing has included the research of modeling methods to predict distortion and residual stresses [10][11][12][13][14], melt pool geometry and energy penetration depth [15,16], microstructure [17,18], or to determine the effect of different process parameters [19,20]. Due to the complexity of the process, simulation techniques vary a great deal, depending on which particular AM process is being implemented and what feature or parameter is the central interest of the study.…”

Section: Introductionmentioning

confidence: 99%

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

Yang

Allen

London

et al. 2019

Integr Mater Manuf Innov

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The laser powder bed fusion (LPBF) process involves using a laser beam to selectively melt metal powder with a desired shape on a substrate to create a part layer-by-layer. As an Additive Manufacturing (AM) process, laser powder bed fusion (commonly referred to as selective laser melting-SLM) offers superior design freedom over conventional manufacturing methods and enables the production of complex, lightweight geometries with applications in the aerospace, automotive, and biomedical industries. In addition to enhanced design freedom, AM technologies provide improved material utilization and allow for reduced assembly needs. However, the reliability and repeatability of additively manufactured parts is a challenge to the wide-scale adoption of the technology for safety critical parts. A critical limitation of process optimization is the prediction and control of residual stresses, distortion, and microstructure evolution. This work focuses on the development and implementation of a numerical modeling technique for the prediction of residual strains within an Inconel 625 LPBF part. The model, using the SIMULIA Additive Manufacturing Scenario App, based on the Abaqus 2018 finite element solver, was developed and analyzed as part of a submission for the NIST AM Benchmark 2018. A sequentially coupled thermo-mechanical analysis was adopted to replicate the building conditions of a single cantilever beam built at the NIST laboratories. The results of the blind study were compared to X-ray diffraction (XRD) measurements of the physical build. The predicted three-dimensional residual strain field showed a high level of accuracy and the submission described in this paper received joint first prize in the residual elastic strain category of the NIST AM Benchmark 2018. The results presented in this paper reflect only findings before the benchmark measurements were posted on the NIST website.

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“…A coupled model comprising CA–FEM has been introduced to predict the microstructure alteration during SLM of AA-2024 feedstock. The proposed approach enables the calculation of heat transfer and grain growth, taking into account powder-to-liquid-to-solid transformation [ 121 ]. As CFD analysis can result in more accurate thermal simulation and study of the melt-pool dimension, therefore CFD was coupled with CA to predict the microstructure of Ti-6Al-4V subjected to SLM with a single track [ 122 ].…”

Section: Numerical Simulation Of Slmmentioning

confidence: 99%

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

et al. 2020

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Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.

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Two-dimensional simulation of grain structure growth within selective laser melted AA-2024

Cited by 106 publications

References 26 publications

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Grain Structure Evolution of Al–Cu Alloys in Powder Bed Fusion with Laser Beam for Excellent Mechanical Properties

Residual Strain Predictions for a Powder Bed Fusion Inconel 625 Single Cantilever Part

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

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