Multiscale framework for prediction of residual stress in additively manufactured functionally graded material

Shan, Zhengtong; Tran, Minh Tien; Woo, Wanchuck; Hwang, Seok‐Ho; Wang, Huai; Luzin, Vladimir; Kingston, E.; Hill, Michael R.; DeWald, Adrian T.; Kim, Dong Kyu

doi:10.1016/j.addma.2022.103378

Cited by 5 publications

(2 citation statements)

References 44 publications

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“…According to the superposition principle of Equation (12), the tensile residual stresses generate positive SIF values, which increase the overall SIF and make the DED curve lie above the hot‐rolled plate curve. [ 32,33 ] Compared to the DED model without LSP treatment, the SIF at the front end of the LSP region is significantly larger. It is mainly owing to the overall stress balance of the model during the LSP process resulting in tensile residual stresses in this region.…”

Section: Resultsmentioning

confidence: 99%

Effects of Residual Stress Induced by Laser Shock Peening on Fatigue Crack Propagation Behavior in Directed Energy Deposition Stainless Steel

Duan,

Shang,

Luo

et al. 2023

steel research int.

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To investigate the effect of laser shock peening (LSP) on the fatigue crack propagation behavior of 316L stainless steel fabricated by directed energy deposition (DED), three‐dimensional finite element models of DED and compact tensile specimens before and after LSP are developed. The residual stress fields induced by DED and LSP are simulated, as well as the effects of different residual stresses on the stress intensity factor and effective stress ratio based on the contour integral method is also analyzed. The microstructure of the LSP region is observed by SEM. When the crack length increases from 12 mm to 22.5 mm, the average effective stress ratio of the DED specimen is 0.133, and the average effective stress ratio of the DED specimen after LSP decreases to 0.110, which decreases by 17.3%. The fatigue lives of the DED specimen before and after LSP are 62.7% and 105.2% of that of the hot‐rolled plate. After LSP treatment, the fatigue life of the DED specimen is increased by about 1.68 times. The fracture morphology in the transient fracture zone changes from ductile and brittle mixed fracture to ductile fracture.This article is protected by copyright. All rights reserved.

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Section: Resultsmentioning

confidence: 99%

Effects of Residual Stress Induced by Laser Shock Peening on Fatigue Crack Propagation Behavior in Directed Energy Deposition Stainless Steel

Duan,

Shang,

Luo

et al. 2023

steel research int.

View full text Add to dashboard Cite

show abstract

“…The cells interact with their neighboring cells according to predefined rules, which simulate grain growth, recrystallization, or other microstructural phenomena. Cellular automata models can be used to study phenomena like grain refinement during plastic deformation or recrystallization in heat treatment processes [32]- [36]. These modeling approaches, including crystal plasticity models, phase field methods, and cellular automata, provide valuable insights into the microstructural evolution and behavior of materials during metal processing.…”

Section: Mesoscale Modelingmentioning

confidence: 99%

Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

Bhavana,

Kaushik

et al. 2024

E3S Web Conf.

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Multiscale modeling and simulation offer crucial insights for designing and analyzing metal forming, bending, welding, and casting processes, all of which are vital across automotive, aerospace, and construction industries. This paper overviews multiscale techniques used in these areas. Macroscopically, continuum-based methods like finite element analysis (FEA) model the overall process and its impact on metal materials. FEA reveals deformation, stress distribution, and temperature changes during manufacturing processes. Mesoscale techniques, including crystal plasticity, phase field methods, and cellular automata, focus on microstructural evolution and mechanical properties. They model the behavior of grains and phases within the metal. These models combine macro and mesoscale data for accuracy. This allows for the prediction of grain growth, recrystallization, and phase transformations – critical for optimizing processes, refining component design, and ensuring quality. For example, multiscale modeling successfully captured microstructural evolution during casting (demonstrating ±2% average grain growth deviation) and predicted defect formation in welded joints with high accuracy (demonstrating a 0.95 correlation coefficient with non-destructive testing).

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Residual stress evaluation in innovative layer-level continuous functionally graded materials produced by Powder Bed Fusion-Laser Beam

Campanelli,

Carone,

Casavola

et al. 2024

Int J Adv Manuf Technol

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The main objective of this study is to evaluate residual stresses in AISI 316L and 18Ni Maraging 300 functionally graded materials with continuous variation of composition within a single layer using the contour method. The manufacture of this kind of layer-level continuous functionally graded materials by employing a Powder Bed Fusion-Laser Beam system utilizing a blade/roller-based powder spreading technique has only been recently devised and a proper residual stress analysis is still required. In fact, as the mechanical properties of additively manufactured samples are significantly influenced by the direction of construction, the same holds true for the direction along which the compositional variation is made. Furthermore, in this study, the impact of solution annealing and aging heat treatment, which are necessary for enhancing the mechanical properties of martensitic steel, on residual stresses was explored. Additionally, the effect of adopting material-differentiated process parameters was investigated. The results indicated that each specimen displayed areas of tensile stress concentration on the upper and lower surfaces, balanced by compression in the center. The application of heat treatment led to a decrease in the maximum tensile stress of 8% and provided a uniform and significant stress reduction within the maraging steel. Finally, the implementation of material-specific process parameters for the three composition zones in conjunction with the heat treatment resulted in a reduction in the maximum residual stress of 35% and also a significantly lower residual stress field throughout the specimen.

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Multiscale framework for prediction of residual stress in additively manufactured functionally graded material

Cited by 5 publications

References 44 publications

Effects of Residual Stress Induced by Laser Shock Peening on Fatigue Crack Propagation Behavior in Directed Energy Deposition Stainless Steel

Effects of Residual Stress Induced by Laser Shock Peening on Fatigue Crack Propagation Behavior in Directed Energy Deposition Stainless Steel

Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

Residual stress evaluation in innovative layer-level continuous functionally graded materials produced by Powder Bed Fusion-Laser Beam

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