Process chain simulation of laser powder bed fusion including heat treatment and surface hardening

O'Brien, John; Montgomery, S.D.; Yaghi, A.H.; Afazov, Shukri

doi:10.1016/j.cirpj.2021.01.006

Cited by 17 publications

(18 citation statements)

References 40 publications

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“…Figure 11 compares measurements from the physical parts with simulated distortion predictions for both the as-built and stress relieved parts, demonstrating the validity of the Norton creep law approach for simulating stress relief. O'Brien et al [109] reported that the maximum measured and predicted vertical distortions after cutting the double cantilever beam from the baseplate after LPBF were between 0.84 mm and 0.87 mm respectively, which is less than 4% difference. They also reported that the vertical displacements were less than 0.04 mm for both the predicted and measured vertical displacements after the stress relief step.…”

Section: Heat Treatmentmentioning

confidence: 98%

“…The Norton creep law is commonly used to simulate stress relaxation. O'Brien et al [109] conducted a study where the Norton creep constants for In718 at 980 °C were obtained using a reverse engineering approach. The manufacture of a cantilever beam specimen that was built on a Renishaw AM250 and heat treated (by heating to 980 °C, holding for 2.5 h at 980 °C, and cooling down to room temperature) was simulated using a validated LPBF build model and the Norton creep law approach.…”

Section: Heat Treatmentmentioning

confidence: 99%

“…This was achieved by imposing surface stresses obtained from experimental measurements, although Fig. 11 Results from a study comparing measured and predicted vertical distortion for an as-built and stress relieved cantilever beam for In718 [109] simulation-based surfaces stresses could also be imposed if desired.…”

Section: Machining Operationsmentioning

confidence: 99%

“…Figure 14 shows the simulation of two additive manufacturing process chains using data transfer and mapping techniques detailed in [109]. The first manufacturing process chain consists of AM (or LPBF) followed by HT (or stress relief) and shot-peening (SP).…”

Section: Data Transfermentioning

confidence: 99%

“…Similar approach for LPBF manufacturing process chain of an aero-casing was used and demonstrated in [134]. In both research works [109,136], validated process models have been applied to demonstrate the simulation of a manufacturing process chain, but the validation on the process chain has been highlighted as a future research.…”

Section: Data Transfermentioning

confidence: 99%

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Metal powder bed fusion process chains: an overview of modelling techniques

et al. 2021

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Metal powder bed fusion (MPBF) is not a standalone process, and other manufacturing technologies, such as heat treatment and surface finishing operations, are often required to achieve a high-quality component. To optimise each individual process for a given component, its progression through the full process chain must be considered and understood, which can be achieved through the use of validated models. This article aims to provide an overview of the various modelling techniques that can be utilised in the development of a digital twin for MPBF process chains, including methods for data transfer between physical and digital entities and uncertainty evaluation. An assessment of the current maturity of modelling techniques through the use of technology readiness levels is conducted to understand their maturity. Summary remarks highlighting the advantages and disadvantages in physics-based modelling techniques used in MPBF research domains (i.e. prediction of: powder distortion; temperature; material properties; distortion; residual stresses; as well as topology optimisation), post-processing (i.e. modelling of: machining; heat treatment; and surface engineering), and digital twins (i.e. simulation of manufacturing process chains; interoperability; and computational performance) are provided. Future perspectives for the challenges in these MPBF research domains are also discussed and summarised.

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Section: Heat Treatmentmentioning

confidence: 98%

Section: Heat Treatmentmentioning

confidence: 99%

Section: Machining Operationsmentioning

confidence: 99%

Section: Data Transfermentioning

confidence: 99%

Section: Data Transfermentioning

confidence: 99%

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Metal powder bed fusion process chains: an overview of modelling techniques

et al. 2021

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Fatigue response of AlSi10Mg by laser powder bed fusion: influence of build orientation, heat, and surface treatments

Fini,

Croccolo,

De Agostinis

et al. 2024

Prog Addit Manuf

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The aim of this study is to analyze how the fatigue behavior of AlSi10Mg by laser powder bed fusion is affected by build orientation, heat, and surface treatments. A three-by-three factorial plan has been arranged for this purpose. Particularly, regarding the heat treatment, three levels were considered (as built, age hardening, and stress relief); whereas, for the surface treatment, three levels were investigated (micro-shot-peening, micro-shot-peening plus fine blasting, and machining and lapping following laser powder bed fusion). Regarding the build orientation, the specimens were manufactured using three different build orientations (0°, 45°, and 90°). The obtained data have been statistically analyzed by a three-factor ANOVA-based method. The results, supported by fractographic and micrographic microscopy analyses, indicate that the age-hardening treatment yields the maximum benefits, whereas stress relief may even have a detrimental effect. As for surface treatments, a positive influence of shot-peening has been found.

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