Scanning strategies effect on temperature, residual stress and deformation by multi-laser beam powder bed fusion manufacturing

Zhang, Wenyou; Tong, Min; Harrison, Noel M.

doi:10.1016/j.addma.2020.101507

Cited by 51 publications

(39 citation statements)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…A python-based script for finite element software ABAQUS FEA package (Dassault Systemes, Johnston, SC, USA, 2017) was programmed to convert the macroscale geometry into 286 layer-by-layer slices [ 13 , 24 ]. During the computation for each layer, an element-birth technique [ 13 , 21 , 25 ] was employed. The converged (less than 0.19% nodal temperature difference) mesh size of 23 μm × 23 μm was employed for the part.…”

Section: Methodsmentioning

confidence: 99%

“…The following heat losses were considered in the thermal modelling: heat conduction between the active layer (i.e., the newly added layer of powders) and the solidified material of the previous layer or the base plate, heat radiation at the top surface of the active layer to the chamber. The heat transfer between the powder bed and the side of the solidified part was dealt with in a way similar to heat convection, and the related details can be found in the authors’ previous papers [ 13 , 24 , 25 ]. Due to the fact that the PBF-EB process is normally conducted in a vacuum environment, the heat convection at the top surface of the active layer was not considered in the modelling.…”

Section: Methodsmentioning

confidence: 99%

See 1 more Smart Citation

Material Characterisation and Computational Thermal Modelling of Electron Beam Powder Bed Fusion Additive Manufacturing of Ti2448 Titanium Alloy

Wang

Zhang

et al. 2021

Materials

Self Cite

View full text Add to dashboard Cite

Ti-24Nb-4Zr-8Sn (Ti2448) is a metastable β-type titanium alloy developed for biomedical applications. In this work, cylindrical samples of Ti2448 alloy have been successfully manufactured by using the electron beam powder bed fusion (PBF-EB) technique. The thermal history and microstructure of manufactured samples are characterised using computational and experimental methods. To analyse the influence of thermal history on the microstructure of materials, the thermal process of PBF-EB has been computationally predicted using the layer-by-layer modelling method. The microstructure of the Ti2448 alloy mainly includes β phase and a small amount of α″ phase. By comparing the experimental results of material microstructure with the computational modelling results of material thermal history, it can be seen that aging time and aging temperature lead to the variation of α″ phase content in manufactured samples. The computational modelling proves to be an effective tool that can help experimentalists to understand the influence of macroscopic processes on material microstructural evolution and hence potentially optimise the process parameters of PBF-EB to eliminate or otherwise modify such microstructural gradients.

show abstract

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Material Characterisation and Computational Thermal Modelling of Electron Beam Powder Bed Fusion Additive Manufacturing of Ti2448 Titanium Alloy

Wang

Zhang

et al. 2021

Materials

Self Cite

View full text Add to dashboard Cite

show abstract

“…As can be expected, the elongation improves while the UTS decreases. Nonetheless, the recent use of dual laser beam scanning strategies has shown to be an alternative remedy to the residual stress issue (Zhang et al, 2020b) and shorten the total time exposure (Zhang et al, 2020c). The use of this dual-beam set-up will increase the benefits of the SLM process in terms of a higher building rate and probable surface patterning when multiple lasers are applied.…”

Section: Process Tracking and Quality Evaluationmentioning

confidence: 99%

Selective laser melting: lessons from medical devices industry and other applications

Fé-Perdomo

Ramos‐Grez

Beruvides³

et al. 2021

RPJ

View full text Add to dashboard Cite

Purpose The purpose of this paper is to outline some key aspects such as material systems used, phenomenological and statistical process modeling, techniques applied to monitor the process and optimization approaches reported. All these need to be taken into account for the ongoing development of the SLM technique, particularly in health care applications. The outcomes from this review allow not only to summarize the main features of the process but also to collect a considerable amount of investigation effort so far achieved by the researcher community. Design/methodology/approach This paper reviews four significant areas of the selective laser melting (SLM) process of metallic systems within the scope of medical devices as follows: established and novel materials used, process modeling, process tracking and quality evaluation, and finally, the attempts for optimizing some process features such as surface roughness, porosity and mechanical properties. All the consulted literature has been highly detailed and discussed to understand the current and existing research gaps. Findings With this review, there is a prevailing need for further investigation on copper alloys, particularly when conformal cooling, antibacterial and antiviral properties are sought after. Moreover, artificial intelligence techniques for modeling and optimizing the SLM process parameters are still at a poor application level in this field. Furthermore, plenty of research work needs to be done to improve the existent online monitoring techniques. Research limitations/implications This review is limited only to the materials, models, monitoring methods, and optimization approaches reported on the SLM process for metallic systems, particularly those found in the health care arena. Practical implications SLM is a widely used metal additive manufacturing process due to the possibility of elaborating complex and customized tridimensional parts or components. It is corroborated that SLM produces minimal amounts of waste and enables optimal designs that allow considerable environmental advantages and promotes sustainability. Social implications The key perspectives about the applications of novel materials in the field of medicine are proposed. Originality/value The investigations about SLM contain an increasing amount of knowledge, motivated by the growing interest of the scientific community in this relatively young manufacturing process. This study can be seen as a compilation of relevant researches and findings in the field of the metal printing process.

show abstract

“…Due to the large number of variables involved in the AM process, the combination of experiments and numerical simulations is quite useful to study the thermo-mechanical behavior, duly accounting for the limitations of experimental measurements and the mandatory validation of the computational models [5][6][7][8][9]. In this line, Lu et al [6,7] studied the residual stresses and distortion of Ti-6Al-4V single-wall and rectangular parts using a finite element (FE) model calibrated by establishing an in situ system with integrated infrared imaging sensor, thermocouples, digital image correlation, and displacement sensor, which can measure the detailed temperature and distortion of Ti-6Al-4V parts manufactured by directed energy deposition (DED).…”

Section: Introductionmentioning

confidence: 99%

Residual Stresses Control in Additive Manufacturing

Cervera

Chiumenti

et al. 2021

JMMP

View full text Add to dashboard Cite

Residual stresses are one of the primary causes for the failure of parts or systems in metal additive manufacturing (AM), since they easily induce crack propagation and structural distortion. Although the formation of residual stresses has been extensively studied, the core factors steering their development in AM have not been completely uncovered. To date, several strategies based on reducing the thermal gradients have been developed to mitigate the manifestation of residual stresses in AM; however, how to choose the optimal processing plan is still unclear for AM designers. In this regard, the concept of the yield temperature, related to the thermal deformation and the mechanical constraint, plays a crucial role for controlling the residual stresses, but it has not been duly investigated, and the corresponding approach to control stresses is also yet lacking. To undertake such study, a three-bar model is firstly used to illustrate the formation mechanism of the residual stress and its key causes. Next, an experimentally calibrated thermomechanical finite element model is used to analyze the sensitivity of the residual stresses to the scan pattern, preheating, energy density, and the part geometry and size, as well as the substrate constraints. Based on the numerical results obtained from this analysis, recommendations on how to minimize the residual stresses during the AM process are provided.

show abstract

Scanning strategies effect on temperature, residual stress and deformation by multi-laser beam powder bed fusion manufacturing

Cited by 51 publications

References 28 publications

Material Characterisation and Computational Thermal Modelling of Electron Beam Powder Bed Fusion Additive Manufacturing of Ti2448 Titanium Alloy

Material Characterisation and Computational Thermal Modelling of Electron Beam Powder Bed Fusion Additive Manufacturing of Ti2448 Titanium Alloy

Selective laser melting: lessons from medical devices industry and other applications

Residual Stresses Control in Additive Manufacturing

Contact Info

Product

Resources

About