Residual stress in laser-based directed energy deposition of aluminum alloy 2024: simulation and validation

Alfieri, Vittorio; Bolelli, Giovanni

doi:10.1007/s00170-021-07988-2

Cited by 8 publications

(5 citation statements)

References 55 publications

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“…Moreover, applying additive and subtractive hybrid systems can instantly remove the defects detected or allow instant surface treatment and machining during real-time monitoring. Also, the deposition process's temperature distribution, residual stress, etc., can be predicted and optimized by applying numerical simulation and modeling, thereby providing practical guidance for improving the surface quality and dimensional accuracy of LDED Al alloy components [264,265]. On this basis, defect elimination, high dimensional accuracy, and high surface quality can be successfully achieved in LDED Al alloys to fabricate high-quality parts.…”

Section: Defect and Surface Quality Monitoringmentioning

confidence: 99%

Review on laser directed energy deposited aluminum alloys

Liu,

Chen,

Qiu

et al. 2024

Int. J. Extrem. Manuf.

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The lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing to process high-value Al parts. As a mainstream additive manufacturing technique, laser directed energy deposition (LDED) shows good scalability to meet requirements for large-format components manufacturing and repairing. However, LDED Al alloys are highly challenging due to the inherent poor printability (e.g., low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review gains a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, elements evaporation and resultant inferior mechanical properties (than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improve the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmarking mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. The future opportunities and perspectives in LDED high-performance Al alloys are also outlooked.

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Section: Defect and Surface Quality Monitoringmentioning

confidence: 99%

Review on laser directed energy deposited aluminum alloys

Liu,

Chen,

Qiu

et al. 2024

Int. J. Extrem. Manuf.

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show abstract

“…Furthermore, the software COMSOL Multiphysics has been used to simulate the behavior of the virtual samples aiming at validating the empirical procedure. The mentioned software has been chosen due to the model setting flexibility and the accuracy of the numerical analysis [51].…”

Section: Setting Up the Numerical Simulationmentioning

confidence: 99%

Metal functionally graded gyroids: additive manufacturing, mechanical properties, and simulation

Alfieri

Guillen

Fabbricatore

2022

Int J Adv Manuf Technol

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Functionally graded materials raise considerable interest in the biomedical research. In particular, gyroid structures are suitable for bone tissue engineering applications, allowing to emulate the porosity of the inner part of the bone. In this frame, the mechanical properties of 17–4 PH steel gyroids made by additive manufacturing have been investigated. Three design methods have been implemented, i.e., thickness graded, size graded, and uniform, to address the lack of knowledge in the area of stainless-steel scaffolds aiming at providing a map of the mechanical properties. Compressive mechanical properties absorbed energy and absorption efficiency have been found for the aforementioned design methods. Furthermore, defects and collapse behavior have been analyzed: imperfections have been detected in the thin-walled areas of the graded samples. Nevertheless, under given conditions, the graded samples have mechanical properties comparable to those of uniform ones, exhibiting a controlled layer-by-layer collapse mechanism and consequent weight reduction. The Gibson-Ashby models have been implemented, and the calibration coefficients have been compared with other research works. A FEM-based numerical model has been proposed to reproduce the mechanical properties of the mentioned structures finding critical issues in the representation of defects. In this frame, the resulting Gibson Ashby calibration coefficients are in good agreement with the literature and reveal the graded samples have a bending-dominating behavior sustaining larger strains than the uniform case, giving the ground for high energy absorption applications. Furthermore, the FEM analyses are in good agreement with the literature providing a reliable tool to further investigate the metal functionally graded gyroid field.

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“…The temperature gradient plays a significant role in the formation of dendrite arm spacing. Recently many researchers proposed numerical modeling of the DED process to predict process variables that influence the melt pool, cooling rates, temperature cycles, residual stress, and distortion of various materials, which have been reported elsewhere [120,121].…”

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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Residual stress in laser-based directed energy deposition of aluminum alloy 2024: simulation and validation

Cited by 8 publications

References 55 publications

Review on laser directed energy deposited aluminum alloys

Review on laser directed energy deposited aluminum alloys

Metal functionally graded gyroids: additive manufacturing, mechanical properties, and simulation

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

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