Residual stress development in selective laser-melted Ti6Al4V: a parametric thermal modelling approach

Ali, Haider; Ghadbeigi, Hassan; Mumtaz, Kamran

doi:10.1007/s00170-018-2104-9

Cited by 87 publications

(39 citation statements)

References 40 publications

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“…According to Ahmed et al [58], cooling rates higher than 410°C s leads to a fully martensitic microstructure for Ti6Al4V. The works by Ali et al [40][41][42] show that the cooling rate for all combination of SLM parameters used in this study was higher than 410°C s and therefore lead to martensitic α ′ laths formation in the samples as in Fig. 4a-c. Figure 4d shows that at a bed temperature of 570°C, the sample contains a basket weave (α + β) microstructure with α colonies (highlighted by red circles).…”

Section: Residual Stress Maps Using the Contour Methodsmentioning

confidence: 51%

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Effect of pre-emptive in situ parameter modification on residual stress distributions within selective laser-melted Ti6Al4V components

Ali

Ghadbeigi

Hosseinzadeh

et al. 2019

Int J Adv Manuf Technol

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The effect of thermally induced residual stresses is not dynamically considered during a selective laser melting (SLM) build; instead, it processes using invariable parameters across the entire component's cross-section. This lack of pre-emptive in situ parameter adjustment to reduce residual stresses during processing is a lost opportunity for the process with the potential to improve component mechanical properties. This investigation studied the residual stresses introduced during manufacturing of SLM Ti6Al4V benchmark components and adapted process parameters within a build (layer-to-layer specific modifications) to manage and redistribute stresses within these components. It was found that temporarily switching to an increased layer thickness during the build, directly below highly stressed regions within the component, redistributed stresses and reduced the overall stresses within the structure by 8.5% (within the 80-320-MPa residual stress range) compared to standard invariable SLM processing parameters. This work demonstrates the need for current SLM systems to focus on developing a more intelligent processing architecture with parameters that adapt on the fly during a build, in order to manage residual stresses within the built structure.

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Section: Residual Stress Maps Using the Contour Methodsmentioning

confidence: 51%

“…Ali et al [34,[39][40][41][42] measured residual stress with the strain gage hole-drilling method [34,[39][40][41][42][43][44][45] in SLM Ti6Al4V 30 × 30 × 10 mm blocks. Residual stress is inversely proportional to bed temperature and 570°C bed pre-heat temperature completely mitigated residual stress [42].…”

Section: Effect Of Geometrymentioning

confidence: 99%

Effect of pre-emptive in situ parameter modification on residual stress distributions within selective laser-melted Ti6Al4V components

Ali

Ghadbeigi

Hosseinzadeh

et al. 2019

Int J Adv Manuf Technol

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“…The first laser movement has been incorporated to be exposed onto the powder bed, then heat transfer was used to describe the local temperature field, and finally the solid mechanical model incorporated the derived temperature results to evaluate the imposed residual stress. Temperature-dependent material properties have been combined with phase change from powder–liquid–solid to evaluate imposed residual stress during SLM of Ti6Al4V using the ABAQUS USDFLD subroutine [ 124 ].…”

Section: Numerical Simulation Of Slmmentioning

confidence: 99%

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

et al. 2020

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Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.

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“…3. These aspects lead to the need for numerical simulation [5][6][7]. In the first approximation, the problem of modeling the SLM process is reduced to solving the boundary value problem of thermal conductivity taking into account the phase transitions of the first kind (melting and solidification).…”

Section: Introductionmentioning

confidence: 99%

On possible approaches to visualizing the process of selective laser melting

Molotkov¹,

Tretiyakova²

2019

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This paper deals with the visualization of the previously simulated by the authors selective laser melting process in order to simplify the analysis of the results and the selection of technological parameters of the additive production unit. The article presents two possible approaches for visualization of the selective laser melting process and supported functions, which simplify the work and research in the framework of the new technology. In the twodimensional visualization mode, the emphasis is on the possibility of a more detailed study of the process. In a three-dimensional there is the ability of the broader scope and to see the big picture.

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Residual stress development in selective laser-melted Ti6Al4V: a parametric thermal modelling approach

Cited by 87 publications

References 40 publications

Effect of pre-emptive in situ parameter modification on residual stress distributions within selective laser-melted Ti6Al4V components

Effect of pre-emptive in situ parameter modification on residual stress distributions within selective laser-melted Ti6Al4V components

An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

On possible approaches to visualizing the process of selective laser melting

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