A methodology for precision additive manufacturing through compensation

Afazov, Shukri; Okioga, Annestacy; Holloway, Adam; Denmark, Willem; Triantaphyllou, Andrew; Smith, Sean-Anthony; Bradley-Smith, Liam

doi:10.1016/j.precisioneng.2017.05.014

Cited by 51 publications

(24 citation statements)

References 7 publications

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“…The EBAM process was shown generate RSs lower in magnitude, compared to SLM, but SLM remains one of the most common technologies due to its affordable and simple (no vacuum chamber) set-up. It is important to note that the distortion prevention techniques in which the CAD geometry is altered, such that the distortion during manufacture results in an accurate geometry, as seen in References [98][99][100][101], only enables dimensional accuracy; the RSs still remain in the parts. While the final geometry of the part is correct, the fatigue life and structural integrity of the part might still be affected [10].…”

Section: Discussionmentioning

confidence: 99%

“…Afazov et al [98] developed a method to compensate for the RSs and the subsequent distortions in AM parts. The proposed method used a mathematical model to pre-distort the CAD geometry based on a 3D scan of the distorted, as-built part.…”

Section: Corrective Design To Mitigate Residual Stresses In Ammentioning

confidence: 99%

“…Similar to the work of Afazov et al [98] and Afazov et al [99], Xu et al [100] developed a computational framework to compensate for the distortion in AM processes, to manufacture dimensionally/geometrically accurate parts. The developed process is shown in Figure 27.…”

Section: Corrective Design To Mitigate Residual Stresses In Ammentioning

confidence: 99%

“…The workflow, shown in Figure 26, firstly prints the part from the CAD file, scans the part, and compares the 3D scan data with the CAD geometry; then, it inverts the distortion (while interpolating areas where measurement data are not available) and recreates a corrected surface mesh for printing. Using this distortion-compensation technique on an impeller geometry (110 mm diameter, 40 mm height, with turbine blade height of 80 mm), Inconel 718 parts fabricated in laser powder bed fusion were successful with tolerances of ±65 μm [98]. Afazov et al [99] also implemented a distortion correction, to take advantage of the generated RSs, in order to obtain the correct part geometry.…”

Section: Corrective Design To Mitigate Residual Stresses In Ammentioning

confidence: 99%

“…Using the distortion compensation method, the part distortion was reduced from 200 μm to less than 100 μm [101]. It is important to note that the distortion prevention techniques in which the CAD geometry is altered, such that the distortion during manufacture results in an accurate geometry, as seen in References [98][99][100][101], only enables dimensional accuracy; the RSs still remain in the parts. While the final geometry of the part is correct, the fatigue life and structural integrity of the part might still be In work by Yaghi et al [101], a method for mitigating distortion in AM parts was presented.…”

Section: Corrective Design To Mitigate Residual Stresses In Ammentioning

confidence: 99%

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On Residual Stress Development, Prevention, and Compensation in Metal Additive Manufacturing

Carpenter

Tabei

2020

Materials

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One of the most appealing qualities of additive manufacturing (AM) is the ability to produce complex geometries faster than most traditional methods. The trade-off for this advantage is that AM parts are extremely vulnerable to residual stresses (RSs), which may lead to geometrical distortions and quality inspection failures. Additionally, tensile RSs negatively impact the fatigue life and other mechanical performance characteristics of the parts in service. Therefore, in order for AM to cross the borders of prototyping toward a viable manufacturing process, the major challenge of RS development must be addressed. Different AM technologies contain many unique features and parameters, which influence the temperature gradients in the part and lead to development of RSs. The stresses formed in AM parts are typically observed to be compressive in the center of the part and tensile on the top layers. To mitigate these stresses, process parameters must be optimized, which requires exhaustive and costly experimentations. Alternative to experiments, holistic computational frameworks which can capture much of the physics while balancing computational costs are introduced for rapid and inexpensive investigation into development and prevention of RSs in AM. In this review, the focus is on metal additive manufacturing, referred to simply as “AM”, and, after a brief introduction to various AM technologies and thermoelastic mechanics, prior works on sources of RSs in AM are discussed. Furthermore, the state-of-the-art knowledge on RS measurement techniques, the influence of AM process parameters, current modeling approaches, and distortion prevention approaches are reported.

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