Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS

Johnson, Kyle L.; Rodgers, Theron; Underwood, Olivia De'Haven; Madison, Jonathan D; Ford, Kurtis Ross; Whetten, Shaun R; Dagel, Daryl; Bishop, Joseph E.

doi:10.1007/s00466-017-1516-y

Cited by 66 publications

(26 citation statements)

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“…Selective laser melting (SLM), as a typical additive manufacturing (AM) technique, enables the quick production of complex shaped three-dimensional (3D) parts directly from metal powders. Up to now, a large number of studies about SLM-AM or electron-beam-AM have been focused on structural materials with mechanical properties as the focus, such as aluminium alloys [5], Ti-Al-V alloys [6][7][8], Ni-based superalloys [9], stainless steel [10,11], etc. In contrast, the application of SLM-AM to functional materials is still in its infancy.…”

Section: Introductionmentioning

confidence: 99%

Computational study on microstructure evolution and magnetic property of laser additively manufactured magnetic materials

Gutfleisch

2019

Comput Mech

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IAdditive manufacturing (AM) offers an unprecedented opportunity for the quick production of complex shaped parts directly from a powder precursor. But its application to functional materials in general and magnetic materials in particular is still at the very beginning. Here we present the first attempt to computationally study the microstructure evolution and magnetic properties of magnetic materials (e.g. Fe-Ni alloys) processed by selective laser melting (SLM). SLM process induced thermal history and thus the residual stress distribution in Fe-Ni alloys are calculated by finite element analysis (FEA). The evolution and distribution of the γ-Fe-Ni and FeNi 3 phase fractions were predicted by using the temperature information from FEA and the output from CALculation of PHAse Diagrams (CALPHAD). Based on the relation between residual stress and magnetoelastic energy, magnetic properties of SLM processed Fe-Ni alloys (magnetic coercivity, remanent magnetization, and magnetic domain structure) are examined by micromagnetic simulations. The calculated coercivity is found to be in line with the experimentally measured values of SLM-processed Fe-Ni alloys. This computation study demonstrates a feasible approach for the simulation of additively manufactured magnetic materials by integrating FEA, CAL-PHAD, and micromagnetics.

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Section: Introductionmentioning

confidence: 99%

Computational study on microstructure evolution and magnetic property of laser additively manufactured magnetic materials

Gutfleisch

2019

Comput Mech

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“…22 Several experimental investigations have also studied variation within an AM build. [23][24][25][26] The study presented in this article focuses on microstructure and property variation between disparate AM processes rather than spatial variation within a single build. In this article, we evaluate the influence of process-induced variation in AM microstructures using a fully computational approach.…”

Section: Introductionmentioning

confidence: 99%

Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties

Rodgers

Lim

Brown

2019

JOM

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Metal additive manufacturing (AM) allows for the freeform creation of complex parts. However, AM microstructures are highly sensitive to the process parameters used. Resulting microstructures vary significantly from typical metal alloys in grain morphology distributions, defect populations and crystallographic texture. AM microstructures are often anisotropic and possess three-dimensional features. These microstructural features determine the mechanical properties of AM parts. Here, we reproduce three ''canonical'' AM microstructures from the literature and investigate their mechanical responses. Stochastic volume elements are generated with a kinetic Monte Carlo process simulation. A crystal plasticity-finite element model is then used to simulate plastic deformation of the AM microstructures and a reference equiaxed microstructure. Results demonstrate that AM microstructures possess significant variability in strength and plastic anisotropy compared with conventional equiaxed microstructures.

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“…[4][5][6][7][8] Modeling and simulation of AM processes is particularly challenging, since it involves multiple time and space scales.9 Furthermore, metal-based AM involves multiple physics, and is thus multidisciplinary in nature, requiring interdisciplinary research efforts. Fortunately, the unique manufacturing process of AM affords the possibility of tight integration of in situ measurements and computational modeling.…”

mentioning

confidence: 99%

“…[4][5][6][7][8] Modeling and simulation of AM processes is particularly challenging, since it involves multiple time and space scales.…”

mentioning

confidence: 99%

“…[1][2][3] However, full realization of the possibilities of metal-based AM will require significant advances in both the process and performance modeling of additively manufactured materials and structures. [4][5][6][7][8] Modeling and simulation of AM processes is particularly challenging, since it involves multiple time and space scales. 9 Furthermore, metal-based AM involves multiple physics, and is thus multidisciplinary in nature, requiring interdisciplinary research efforts.…”

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confidence: 99%

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Integrated Computational and Experimental Methods for Additive Manufacturing

Bishop

Clarke

Wagner

2018

JOM

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Additive manufacturing (AM) holds the promise of revolutionizing current paradigms in engineering design, manufacturing, and material and structural performance.1-3 However, full realization of the possibilities of metal-based AM will require significant advances in both the process and performance modeling of additively manufactured materials and structures. [4][5][6][7][8] Modeling and simulation of AM processes is particularly challenging, since it involves multiple time and space scales.9 Furthermore, metal-based AM involves multiple physics, and is thus multidisciplinary in nature, requiring interdisciplinary research efforts. Fortunately, the unique manufacturing process of AM affords the possibility of tight integration of in situ measurements and computational modeling.10-12 Significant challenges remain, however, in material/structural qualification and development of process-structureproperties-performance linkages. [13][14][15][16][17] The recent 3rd Sandia Fracture Challenge focused on metal AM is an interesting example of the challenges involved in predicting the performance of AM components, even provided with significant a priori information of the as-built structure. 18With the goal of fostering communication and collaborations between the AM computational and experimental communities, a conference was recently held at the Colorado School of Mines, on September 6-8, 2017. 19 The conference brought together researchers from both the computational mechanics and materials science research communities involved in advancing the state of the art in process and performance modeling of additively manufactured (AM) materials and structures. There were over 31 invited speakers from academia, industry, and national laboratories, organized in a single-track session to foster communication. A central theme of the conference was integration of computational modeling and experiments, leveraging the unique manufacturing aspects of AM, to improve overall modeling predictivity and enable process optimization. This conference was jointly sponsored by the U. While the conference did not have published proceedings, presenters were invited to submit articles for a special topic in JOM. The following three articles have been assembled from this process. The first article by Roehling et al. describes the use of single-track laser-melting experiments to explore process parameters and their effects on microstructure. Experimental results were used to benchmark a phase-field model that simulated the rapid solidification in conditions relevant for AM. The second paper by Lindwall et al. models the creation of bulk metallic glasses using a powder-bed fusion process. The study evaluates computational approaches that can be used to increase the computational speed while maintaining accurate temperatures in critical regions. The accurate prediction of temperature history is particularly important in ensuring that reheated material does not become devitrified. The third paper by Donoso and Peters uses a combined discrete-contin...

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Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS

Cited by 66 publications

References 50 publications

Computational study on microstructure evolution and magnetic property of laser additively manufactured magnetic materials

Computational study on microstructure evolution and magnetic property of laser additively manufactured magnetic materials

Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties

Integrated Computational and Experimental Methods for Additive Manufacturing

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