Comprehensive review on residual stress control strategies in laser-based powder bed fusion process– Challenges and opportunities

Kumar, Vijay; Jebaraj, A. Vinoth

doi:10.1007/s40516-023-00217-6

Cited by 8 publications

(2 citation statements)

References 161 publications

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“…Moreover, due to the presence of substantial thermal gradients present in various AM techniques during the progressive solidification of layers, notable residual stresses can emerge [450][451][452]. These stresses often result in distortions such as part warping and other geometric deviations.…”

Section: General Considerations About Additive Manufacture For Topolo...mentioning

confidence: 99%

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

Hurtado-Pérez,

Pablo-Sotelo,

Ramírez-López

et al. 2023

Aerospace

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Launching satellites into the Earth’s orbit is a critical area of research, and very demanding satellite services increase exponentially as modern society takes shape. At the same time, the costs of developing and launching satellite missions with shorter development times increase the requirements of novel approaches in the several engineering areas required to build, test, launch, and operate satellites in the Earth’s orbit, as well as in orbits around other celestial bodies. One area with the potential to save launching costs is that of the structural integrity of satellites, particularly in the launching phase where the largest vibrations due to the rocket motion and subsequent stresses could impact the survival ability of the satellite. To address this problem, two important areas of engineering join together to provide novel, complete, and competitive solutions: topology optimisation methods and additive manufacturing. On one side, topology optimisation methods are mathematical methods that allow iteratively optimising structures (usually by decreasing mass) while improving some structural properties depending on the application (load capacity, for instance), through the maximisation or minimisation of a uni- or multi-objective function and multiple types of algorithms. This area has been widely active in general for the last 30 years and has two main core types of algorithms: continuum methods that modify continuous parameters such as density, and discrete methods that work by adding and deleting material elements in a meshing context. On the other side, additive manufacturing techniques are more recent manufacturing processes aimed at revolutionising manufacturing and supply chains. The main exponents of additive manufacturing are Selective Laser Melting (SLM) (3D printing) as well as Electron Beam Melting (EBM). Recent trends show that topology-optimised structures built with novel materials through additive manufacturing processes may provide cheaper state-of-the-art structures that are fully optimised to better perform in the outer-space environment, particularly as part of the structure subsystem of novel satellite systems. This work aims to present an extended review of the main methods of structural topology optimisation as well as additive manufacture in the aerospace field, with a particular focus on satellite structures, which may set the arena for the development of future satellite structures in the next five to ten years.

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Section: General Considerations About Additive Manufacture For Topolo...mentioning

confidence: 99%

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

Hurtado-Pérez,

Pablo-Sotelo,

Ramírez-López

et al. 2023

Aerospace

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“…To do this, let the features be labeled 1, 2, …, nf, and let them respectively take g1, g2, …, gnf time steps, respectively, to be traced by the laser. After the ith feature is scanned (i∈{1,2, ⋯, nf}), the corresponding feature-level state-space representation can be written as: (17) where lq is feature-level time index which can be unique for each feature. SF(lq) refers to the scanned features set at time step lq.…”

Section: Incorporation Of Ability To Handle Arbitrary Part Geometries...mentioning

confidence: 99%

Generalized SmartScan: An Intelligent LPBF Scan Sequence Optimization Approach for 3D Part Geometries

He,

Bugdayci,

Okwudire

2023

Preprint

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Laser powder bed fusion (LPBF) is an additive manufacturing technique that is gaining popularity for producing metallic parts in various industries. However, parts produced by LPBF are prone to residual stress, deformation, cracks and other quality defects due to uneven temperature distribution during the LPBF process. To address this issue, in prior work, the authors have proposed SmartScan, a method for determining laser scan sequence in LPBF using a model-based and optimization-driven approach, rather than using heuristics, and applied it to simple 2D geometries. This paper presents a generalized SmartScan methodology that is applicable to arbitrary 3D geometries. This is achieved by: (1) expanding the thermal model and optimization approach used in SmartScan to multiple layers; (2) enabling SmartScan to process shapes with arbitrary contours and infill patterns within each layer and (3) providing SmartScan with global foresight to make it less myopic in its optimization. Sample 3D parts are printed using the proposed generalized SmartScan and compared to those printed using standard heuristic scan sequences. Reductions of up to 93% in temperature inhomogeneity, 87% in residual stress, and 26% in maximum deformation were observed, without significantly sacrificing print speed. We have to objectively mention the weaknesses. Saying that 20% is not significant is inaccurate.

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The impact of energy density and process parameters on the distribution of residual stresses in additively manufactured stainless steel 316 L

Haribaskar,

Kumar

2024

Appl. Phys. A

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Comprehensive review on residual stress control strategies in laser-based powder bed fusion process– Challenges and opportunities

Cited by 8 publications

References 161 publications

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

Generalized SmartScan: An Intelligent LPBF Scan Sequence Optimization Approach for 3D Part Geometries

The impact of energy density and process parameters on the distribution of residual stresses in additively manufactured stainless steel 316 L

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