Distortion prediction and compensation in selective laser melting

Afazov, Shukri; Denmark, Willem; Toralles, B. Lazaro; Holloway, Adam; Yaghi, A.H.

doi:10.1016/j.addma.2017.07.005

Cited by 96 publications

(61 citation statements)

References 10 publications

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“…Afazov et al [99] also implemented a distortion correction, to take advantage of the generated RSs, in order to obtain the correct part geometry. SLM was modeled with finite element analysis using Ti-6Al-4V powder.…”

Section: Corrective Design To Mitigate Residual Stresses In Ammentioning

confidence: 99%

“…The coordinates of the mesh were updated based on the inverted distortion prediction. It was shown that the non-corrected geometry had distortion of ±200 m, and the corrected geometry from the FEA resulted in distortions of ±45 m [99].…”

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%

“…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. SLM was modeled with finite element analysis using Ti-6Al-4V powder.…”

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%

See 4 more Smart Citations

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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Section: Corrective Design To Mitigate Residual Stresses In Ammentioning

confidence: 99%

Section: Corrective Design To Mitigate Residual Stresses In Ammentioning

confidence: 99%