The effect of process parameters on the residual stress of selective laser melted Inconel 718 thin-walled part

Chen, Changpeng; Yin, Junhui; Zhu, Haihong; Zeng, Xiaoyan; Wang, Guoqing; Liu, Ke; Zhu, Junjie; Chang, Shijie

doi:10.1108/rpj-09-2018-0249

Cited by 38 publications

(19 citation statements)

References 44 publications

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“…For the Y-component of stress, as shown in Figure 18(b1)–18(b4), the residual stress of whole the part is small, which is due to the small size in part width and the small temperature gradient perpendicular to the scanning direction (Chen et al , 2019b; Luo et al , 2018). Similar to the X-component of stress, the residual stress at the interface between the part and the substrate is high.…”

Section: Resultsmentioning

confidence: 99%

“…However, the other researchers stated that increasing the laser power led to a reduction in the cooling rate and the high scanning speed caused a low energy density, which both brought low residual stress. Also, a high powder thickness induced a low residual stress due to the decreased energy input (Chen et al , 2019b). The influence of the process parameters was therefore complex because of the differences in material properties and processing conditions.…”

Section: Introductionmentioning

confidence: 99%

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Distribution and evolution of thermal stress in laser powder bed fusion: conduction mode versus keyhole mode

Chen

Xiao

Xue

et al. 2022

RPJ

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Purpose High temperature gradient induces high residual stress, producing an important effect on the part manufacturing during laser powder bed fusion (LPBF). The purpose of this study is to investigate the effect of the molten pool mode on the thermal stress of Ti-6Al-4V alloy during different deposition processes. Design/methodology/approach A coupled thermal-mechanical finite element model was built. The developed model was validated by comparing the numerical results with the experimental data in the maximum molten pool temperature, the molten pool dimension and the residual stress described in the previous work. Findings For the single-track process, the keyhole mode caused an increase in both the maximum stress and the high-stress area compared with the conduction mode. For the multitrack process, a lower tensile stress around the scanning track and a higher compressive stress below the scanning track were found in the keyhole mode. For the multilayer process, the stress along the scanning direction at the middle of the part changed from tensile stress to compressive stress with the increase in the deposition layer number. As the powder layer number increased, the stress along the scanning direction near the top surface of the part decreased while the stress along the deposition direction obviously increased, indicating that the stress along the deposition direction became the dominant stress. The keyhole mode can reduce the residual stress near the top of the part, and the conduction mode was more likely to produce a low residual stress near the bottom of the part. Originality/value The results provide a systematic understanding of thermal stress during the LPBF process.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Distribution and evolution of thermal stress in laser powder bed fusion: conduction mode versus keyhole mode

Chen

Xiao

Xue

et al. 2022

RPJ

Self Cite

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“…The obtained results demonstrated that the consolidated parts' porosity significantly affects the temperature profile during the process. Another effect caused by the high-temperature gradients in the SLM process is the high residual stress (Chen et al, 2019a), which brings undesired consequences such as shrinkage and cracking during service (Chen et al, 2019b).…”

Section: Feedstock Materials Used In the Selective Laser Melting Processmentioning

confidence: 99%

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

Fé-Perdomo

Ramos‐Grez

Beruvides³

et al. 2021

RPJ

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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.

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“…Consequently, precise simulation of stress profiles of SLM elements is critical to understand the process for creating highquality components. Several numerical approaches have been established in recent years by various researchers to understand SLM process-induced behaviors, especially residual stresses, such as Bian et al(2019Bian et al( , 2020, Chen et al(2019aChen et al( , 2019b and Liu et al(2020b). To deal with the temperature distribution inside the material during the SLM processing, some early models incorporated finite element analysis (Khan et al, 2018a(Khan et al, , 2018bLi et al, 2017;Li and Xiong, 2019;Majeed et al, 2019).…”

Section: Introductionmentioning

confidence: 99%

Evolution of temperature and residual stress behavior in selective laser melting of 316L stainless steel across a cooling channel

Khan

Waqar

Koç

2022

RPJ

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Purpose The current investigation aims at observing the influence of the cooling channel on the thermal and residual stress behavior of the selective laser melting (SLM)316L uni-layer thermo-mechanical model. Design/methodology/approach On a thermo-mechanical model with a cooling channel, the effect of scanning direction, parallel and perpendicular and scan spacing was simulated. The effect of underlying solid and powder bases was evaluated on residual stress profile and thermal variables at various locations. Findings The high heat dissipation of solid base due to high cooling rates and steep thermal gradients can reciprocate with smaller melt pool temperature and melt pool size. Given the same scan spacing, residual stresses were found lower when laser scanning was perpendicular to the cooling channel. Moreover, large scan spacing was found to increase residual stresses. Originality/value Cooling channels are increasingly being used in additive manufacturing; however, their effect on the residual stress behavior of the SLM component is not extensively studied. This research can serve as a foundation for further inquiries into the impact of base material design such as cooling channels on manufactured components using SLM.

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The effect of process parameters on the residual stress of selective laser melted Inconel 718 thin-walled part

Cited by 38 publications

References 44 publications

Distribution and evolution of thermal stress in laser powder bed fusion: conduction mode versus keyhole mode

Distribution and evolution of thermal stress in laser powder bed fusion: conduction mode versus keyhole mode

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

Evolution of temperature and residual stress behavior in selective laser melting of 316L stainless steel across a cooling channel

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