Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products

Jing, Hang; Ge, P.; Zhang, Zhao; Chen, J.Q.; Li, Zhong‐Ming; Liu, Wei Wei

doi:10.3390/met12030462

Cited by 8 publications

(3 citation statements)

References 38 publications

(52 reference statements)

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“…By consideration of the melt pool geometry, double ellipsoid heat source model was originally proposed by Goldak et al [49] and then widely used in welding simulations [50][51][52][53]. The double ellipsoid heat source model in laser additive manufacturing can be written as [54][55][56],…”

Section: Double Ellipsoid Heat Source Modelmentioning

confidence: 99%

A Review on Modelling and Simulation of Laser Additive Manufacturing: Heat Transfer, Microstructure Evolutions and Mechanical Properties

Zhang

Wang

2022

Coatings

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Modelling and simulation are very important for revealing the relationship between process parameters and internal variables like grain morphology in solidification, precipitate evolution, and solid-state phase transformation in laser additive manufacturing. The impact of the microstructural changes on mechanical behaviors is also a hot topic in laser additive manufacturing. Here we reviewed key developments in thermal modelling, microstructural simulations, and the predictions of mechanical properties in laser additive manufacturing. A volumetric heat source model, including the Gaussian and double ellipsoid heat sources, is introduced. The main methods used in the simulation of microstructures, including Monte Carlo method, cellular automaton, and phase field method, are mainly described. The impacts of the microstructures on mechanical properties are revealed by the physics-based models including a precipitate evolution based model and dislocation evolution based model and by the crystal plasticity model. The key issues in the modelling and simulation of laser additive manufacturing are addressed.

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Section: Double Ellipsoid Heat Source Modelmentioning

confidence: 99%

A Review on Modelling and Simulation of Laser Additive Manufacturing: Heat Transfer, Microstructure Evolutions and Mechanical Properties

Zhang

Wang

2022

Coatings

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“…Thus, delamination occurred in the sample is shown in Figure 7b. Jing et al [116] used a sequentially coupled thermomechanical model to predict and understand the behavior of substrate structure for the deposition of TiAl6V4 in the DED process. It was concluded that the long strip with holes substrate structure reduces the tensile residual stress by 20%.…”

Section: Thermomechanical Modelling Of Ded Processmentioning

confidence: 99%

Reclamation of intermetallic titanium aluminide aero-engine components using directed energy deposition technology

Mallikarjuna

Reutzel

2022

Manufacturing Rev.

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Titanium Aluminide (TiAl) alloys are intermetallics that offer low density, high melting point, good oxidation and corrosion resistance compared to Ni-based superalloys. As a result, these alloys are used in aero-engine parts such as turbine blades, fuel injectors, radial diffusers, divergent flaps, and more. During operation, aero-engine components are subjected to high thermal loading in an oxidizing and corrosive environment, which results in wear and other material damage. Replacement of the entire component may not be desirable due to long lead time and expense. In such cases, repair and refurbishing may be the best option for the reclamation of TiAl parts. Unfortunately, approved repair technology is not currently available for TiAl based components. Additive Manufacturing (AM) based Directed Energy Deposition (DED) may serve as an option to help repair and restore expensive aero-engine parts. In this work, a review of efforts to utilize the DED technique to repair damaged TiAl-based aerospace parts locally is conducted. Replacing the entire TiAl part is not advisable as it is expensive. DED is a promising technique used to produce, repair, rework, and overhaul (MRO) damaged parts. Considering the high-quality standard of the aircraft industry, DED repaired TiAl parts to be certified for their future use in the aircraft is very important. However, there are no standards for the certification of TiAl repaired parts is reported. Case studies reveal that DED is under consideration for repair of TiAl parts. Hybrid technology comprising machining, repair and finishing capability in a single machine is an attractive implementation strategy to improve repair efficacies. The review shows that the investigations into development and applications of DED-based repairing techniques are limited, which suggests that further investigations are very much needed.

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“…It was found that the retained compressive residual stress had a positive effect on the structure. Jing et al [19] presented a new method for controlling residual stress in laser directed energy deposition additive manufacturing products, and results showed that weaker constraints on the substrate can greatly reduce residual stress in additively manufactured products. A.S. Wu et al [20] used experimental methods (digital image correlation combined with build plate removal and sectioning combined with neutron diffraction) to investigate the effects of laser scanning mode, power, scanning speed and build direction on residual stress in powder bed fusion additive manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Residual stress analysis of TC4/Inconel718 functionally graded material produced by laser additive manufacturing based on progressive activation element method

Zhao,

Gao,

Wang

et al. 2023

Int J Adv Manuf Technol

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With the continuous development of preparation technology, laser additive manufacturing (LAM) has become one of the effective ways to manufacture functionally graded materials due to its unique layerby-layer stacking technology. However, the repeated and repeated rapid heating and cooling processes in the manufacturing process will generate large residual stress inside the structure, resulting in the destruction of the structure. In this paper, based on a new nite element method called progressive activation element method (PAE), a thermomechanical coupling model for simulating the process of LAM is established, and the in uence of laser power and composition ratio of transition layers on the residual stress of the overall structure is discussed. The results show that there is a positive correlation between the laser power and the residual stress. The PAE method is compared with the traditional "Model Change" method, and it is found that the PAE method has advantages in computational e ciency, especially when calculating the residual stress of functionally graded materials, the e ciency can be improved by about 1650%. When the TC4/Inconel718 functionally graded material is prepared experimentally, the optimal composition ratio of the transition layers is 8:2. This paper provides reference for the understanding and reasonable suppression of residual stress of functionally graded materials in LAM.

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Numerical Studies of the Effects of the Substrate Structure on the Residual Stress in Laser Directed Energy Additive Manufacturing of Thin-Walled Products

Cited by 8 publications

References 38 publications

A Review on Modelling and Simulation of Laser Additive Manufacturing: Heat Transfer, Microstructure Evolutions and Mechanical Properties

A Review on Modelling and Simulation of Laser Additive Manufacturing: Heat Transfer, Microstructure Evolutions and Mechanical Properties

Reclamation of intermetallic titanium aluminide aero-engine components using directed energy deposition technology

Residual stress analysis of TC4/Inconel718 functionally graded material produced by laser additive manufacturing based on progressive activation element method

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