Consumable development to tailor residual stress in parts fabricated using directed energy deposition processes

Bunn, Jeffrey R.; Kottman, Michael; Fancher, Chris M.; Payzant, E. Andrew; Noakes, Mark W.; Nycz, Andrzej; Love, Lonnie J.; Narayanan, Badri; Babu, Sudarsanam Suresh

doi:10.1016/j.addma.2021.101837

Cited by 5 publications

(5 citation statements)

References 37 publications

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“…The increased welding passes was reported to increase the interpass heat input [31]. It is suggested to cause localized heat treatment around the passes boudaries since the excessive heat causes release in the internal stresses and therefore reduced hardness [35].…”

Section: Resultsmentioning

confidence: 99%

Study the Influence of Welding Parameters by Taguchi’s Design on the Mechanical Properties of Welded Mild Steel (S235jr)

Elfallah

2023

Jurnal Teknologi

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Gas metal arc welding is a leading process in fusion welding with increased productivity and good quality. The welding parameters are crucial in determining welding quality, cost, and productivity. In this study, mild steel with a 10-mm-thick sheet was welded by gas metal arc welding under predetermined parameters of welding voltage, wire feed speed, and groove shape. The analysis made by Taguchi’s design to investigate the effect of these parameters on tensile strength and Vickers micro-hardness of welding. The microstructure of the fusion zone and heat-affected zone is analyzed to monitor their change concerning the mechanical properties. The results showed that tensile strength decreased with decreased hardness. Also, the tensile strength and hardness were higher (a maximum of 305 MPa and 2170 HVN) at welding made at a lower voltage (20 volts), lower wire feed speed (5.9 m/min), and V-shaped base metal groove. The increased precipitation of perlite structure was shown during welding, which has lower tensile strength and hardness. Widmanstatten ferrite and coarser α-ferrite were presented for welding with a lower cooling time. Taguchi’s design showed that voltage at 20 volts has the highest effect on tensile strength, followed by wire feed speed at 5.9 m/min and V-shaped welding.

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Section: Resultsmentioning

confidence: 99%

Study the Influence of Welding Parameters by Taguchi’s Design on the Mechanical Properties of Welded Mild Steel (S235jr)

Elfallah

2023

Jurnal Teknologi

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“…Two steel alloys, mild steel (MS), and a low-temperature transformation (LTT) steel [ 9 ], were used. The two alloys were selected to produce different residual stress distributions, as the austenite to martensite transformation in the LTT steel is known to modify the stress state due to the volume difference between the two phases [ 4 ]. The differences in the complexity of the resulting stress patterns provide a useful test case for the GPR approach.…”

Section: Methodsmentioning

confidence: 99%

“…The advancement of additive manufacturing underscores the need to develop new approaches for mitigating how stresses evolve [ 3 ]. For example, applying lessons designed for controlling the stress state during welding, such as low-temperature transformation materials, has shown promise for tuning stresses in wire-arc additively printed components [ 4 ]. Understanding how stresses evolve with changes in build strategies and materials is critical for developing new approaches for controlling and limiting stress-induced failures.…”

Section: Introductionmentioning

confidence: 99%

“…For example, a single one-dimensional line of data is needed to determine the stress state in a welded plate [ 6 ]. The layer-by-layer nature of additive manufacturing results in a thermal history that can introduce a more complex stress state [ 4 , 5 ]. These complexities often necessitate the measurement of higher dimensional maps to capture underlying variations in the stress state [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

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Validating the Use of Gaussian Process Regression for Adaptive Mapping of Residual Stress Fields

et al. 2023

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Probing the stress state using a high density of measurement points is time intensive and presents a limitation for what is experimentally feasible. Alternatively, individual strain fields used for determining stresses can be reconstructed from a subset of points using a Gaussian process regression (GPR). Results presented in this paper evidence that determining stresses from reconstructed strain fields is a viable approach for reducing the number of measurements needed to fully sample a component’s stress state. The approach was demonstrated by reconstructing the stress fields in wire-arc additively manufactured walls fabricated using either a mild steel or low-temperature transition feedstock. Effects of errors in individual GP reconstructed strain maps and how these errors propagate to the final stress maps were assessed. Implications of the initial sampling approach and how localized strains affect convergence are explored to give guidance on how best to implement a dynamic sampling experiment.

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“…In principle, this approach may include the design of residual stress distributions, for example to tune tensile-compressive asymmetry 9 or prevent fatigue crack initiation and slow fatigue crack propagation 19 . Recent research has investigated the use of LTT steels in AM processes to achieve unique and complex residual stress states 20 – 22 . Yet, process conditions 22 and phase transformations 23 have complex interacting effects on the resulting residual stress distribution, which are further dependent upon thermal contraction, accumulation and annealing of plastic strain, and the temperature dependence of the stress state and material properties.…”

Section: Introductionmentioning

confidence: 99%

Operando neutron diffraction reveals mechanisms for controlled strain evolution in 3D printing

et al. 2023

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Residual stresses affect the performance and reliability of most manufactured goods and are prevalent in casting, welding, and additive manufacturing (AM, 3D printing). Residual stresses are associated with plastic strain gradients accrued due to transient thermal stress. Complex thermal conditions in AM produce similarly complex residual stress patterns. However, measuring real-time effects of processing on stress evolution is not possible with conventional techniques. Here we use operando neutron diffraction to characterize transient phase transformations and lattice strain evolution during AM of a low-temperature transformation steel. Combining diffraction, infrared and simulation data reveals that elastic and plastic strain distributions are controlled by motion of the face-centered cubic and body-centered cubic phase boundary. Our results provide a new pathway to design residual stress states and property distributions within additively manufactured components. These findings will enable control of residual stress distributions for advantages such as improved fatigue life or resistance to stress-corrosion cracking.

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Consumable development to tailor residual stress in parts fabricated using directed energy deposition processes

Cited by 5 publications

References 37 publications

Study the Influence of Welding Parameters by Taguchi’s Design on the Mechanical Properties of Welded Mild Steel (S235jr)

Study the Influence of Welding Parameters by Taguchi’s Design on the Mechanical Properties of Welded Mild Steel (S235jr)

Validating the Use of Gaussian Process Regression for Adaptive Mapping of Residual Stress Fields

Operando neutron diffraction reveals mechanisms for controlled strain evolution in 3D printing

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