An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel

Wu, Amanda S.; Brown, Donald W.; Kumar, Mukul; Gallegos, G. F.; King, Wayne E.

doi:10.1007/s11661-014-2549-x

Cited by 543 publications

(248 citation statements)

References 45 publications

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“…build plate heating; reheating of the melt pool) is commonly used [15,22]. Adapting scanning strategies can also have a strong impact on residual stresses [15,23]. As a post treatment, annealing is widely used and has demonstrated in some cases a 70 percent reduction of residual stresses [24].…”

Section: Introductionmentioning

confidence: 99%

Tailoring residual stress profile of Selective Laser Melted parts by Laser Shock Peening

Kalentics

Boillat

Peyre

et al. 2017

Additive Manufacturing

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Selective laser melting Laser shock peening 3D Laser shock peening Residual stress profile 15-5 PH stainless steel 316L stainless steel a b s t r a c t The paper describes a new approach in controlling and tailoring residual stress profile of parts made by Selective Laser Melting (SLM). SLM parts are well known for the high tensile stresses in the as -built state in the surface or subsurface region. These stresses have a detrimental effect on the mechanical properties and especially on the fatigue life. Laser Shock Peening (LSP) as a surface treatment method was applied on SLM parts and residual stress measurements with the hole -drilling method were performed. Two different grades of stainless steel were used: a martensitic 15-5 precipitation hardenable PH1 and an austenitic 316L. Different LSP parameters were used, varying laser energy, shot overlap, laser spot size and treatments with and without an ablative medium. For both materials the as-built (AB) residual stress state was changed to a more beneficial compressive state. The value and the depth of the compressive stress was analyzed and showed a clear dependence on the LSP processing parameters. Application of LSP on SLM parts showed promising results, and a novel method that would combine these two processes is proposed. The use of LSP during the building phase of SLM as a "3D LSP" method would possibly give the advantage of further increasing the depth and volume of compressive residual stresses, and selectively treating key areas of the part, thereby further increasing fatigue life.

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Section: Introductionmentioning

confidence: 99%

Tailoring residual stress profile of Selective Laser Melted parts by Laser Shock Peening

Kalentics

Boillat

Peyre

et al. 2017

Additive Manufacturing

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“…In powder bed fusion (PBF) and direct energy deposition (DED) parts, the residual stresses are always compressive in the center and tensile at the edge [41][42][43][44]. Some researchers have been conducted to relieve the residual stresses, like preheating the substrate [40] and applying island scanning [45,46]. In this research, the FDM in AM processes is mainly studied.…”

Section: Additive Manufacturingmentioning

confidence: 99%

Integration of physically-based and data-driven approaches for thermal field prediction in additive manufacturing

Jin

2018

Materials & Design

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A quantitative understanding of thermal field evolution is vital for quality control in additive manufacturing (AM). Because of the unknown material parameters, high computational costs, and imperfect understanding of the underlying science, physically-based approaches alone are insufficient for component-scale thermal field prediction. Here, I present a new framework that integrates physically-based and data-driven approaches with quasi in situ thermal imaging to address this problem. The framework consists of (i) thermal modeling using 3D finite element analysis (FEA), (ii) surrogate modeling using functional Gaussian process, and (iii) Bayesian calibration using the thermal imaging data. Based on heat transfer laws, I first investigate the transient thermal behavior during AM using 3D FEA. A functional Gaussian process-based surrogate model is then constructed to reduce the computational costs from the high-fidelity, physically-based model. I finally employ a Bayesian calibration method, which incorporates the surrogate model and thermal measurements, to enable layer-to-layer thermal field prediction across the whole component. A case study on fused deposition modeling is conducted for components with 7 to 16 layers. The cross-validation results show that the proposed framework allows for accurate and fast thermal field prediction for components with different process settings and geometric designs. Integration of Physically-based and Data-driven Approaches for Thermal Field Prediction in Additive ManufacturingJingran Li GENERAL AUDIENCE ABSTRACT This paper aims to achieve the layer to layer temperature monitoring and consequently predict the temperature distribution for any new freeform geometry. An engineering statistical synergistic model is proposed to integrate the pure statistical methods and finite element modeling (FEM), which is physically meaningful as well as accurate for temperature prediction. Besides, this proposed synergistic model contains geometry information, which can be applied to any freeform geometry. This paper serves to enable a holistic cyber physical systems-based approach for the additive manufacturing (AM) not only restricted in fused deposition modeling (FDM) process but also can be extended to powder-based process like laser engineered net shaping (LENS) and selective laser sintering (SLS). This paper as well as the scheduled future works will make it affordable for customized AM including customized geometries and materials, which will greatly accelerate the transition from rapid prototyping to rapid manufacturing. This article demonstrates a first evaluation of engineering statistical synergistic model in AM technology, which gives a perspective on future researches about online quality monitoring and control of AM based data fusion principles. iv ACKNOWLEDGEMENTS

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“…The cold rolled sheet was annealed to remove external stresses, but the PBF sheet was used in the experiments as built. According to Wu et al, the PBF-produced 316L sheets typically have high compressive stress in the center, and tensile stress near surfaces [31]. Still, considering that the properties of traditional and 3D printed materials seem to be very close to each other, it can be expected that the results in laser engraving should differ by a few percentage points at most, despite how rough the surface of a 3D printed part is.…”

Section: Differences In Physical Propertiesmentioning

confidence: 99%

Comparison of Laser-Engraved Hole Properties between Cold-Rolled and Laser Additive Manufactured Stainless Steel Sheets

et al. 2017

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Laser drilling and laser engraving are common manufacturing processes that are found in many applications. With the continuous progress of additive manufacturing (3D printing), these processes can now be applied to the materials used in 3D printing. However, there is a lack of knowledge about how these new materials behave when processed or machined. In this study, sheets of 316L stainless steel produced by both the traditional cold rolling method and by powder bed fusion (PBF) were laser drilled by a nanosecond pulsed fiber laser. Results were then analyzed to find out whether there are measurable differences in laser processing parts that are produced by either PBF (3D printing) or traditional steel parts. Hole diameters, the widths of burn effects, material removal rates, and hole tapers were measured and compared. Additionally, differences in microstructures of the samples were also analyzed and compared. Results show negligible differences in terms of material processing efficiency. The only significant differences were that the PBF sample had a wider burn effect, and had some defects in the microstructure that were more closely analyzed. The defects were found to be shallow recesses in the material. Some of the defects were deep within the material, at the end and start points of the laser lines, and some were close to the surfaces of the sample.

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An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel

Cited by 543 publications

References 45 publications

Tailoring residual stress profile of Selective Laser Melted parts by Laser Shock Peening

Tailoring residual stress profile of Selective Laser Melted parts by Laser Shock Peening

Integration of physically-based and data-driven approaches for thermal field prediction in additive manufacturing

Comparison of Laser-Engraved Hole Properties between Cold-Rolled and Laser Additive Manufactured Stainless Steel Sheets

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