Thermal modeling in metal additive manufacturing using graph theory – Application to laser powder bed fusion of a large volume impeller

Yavari, Reza; Williams, R. J. P.; Riensche, Alex; Hooper, Paul A.; Cole, Kevin D.; Jacquemetton, Lars; Halliday, Harold; Rao, Prahalada

doi:10.1016/j.addma.2021.101956

Cited by 24 publications

(5 citation statements)

References 38 publications

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“…In contrast, LPBF with metal printing is indispensable for achieving high-performance functionalities [13]. Numerous studies underscore the successful application of LPBF in printing open impellers, encompassing investigations into material properties, thermal history predictions, and optimization of process parameters [14][15][16]. Significantly, LPBF allows for the fabrication of impellers from recycled materials, accentuating its potential for sustainable manufacturing practices [17].…”

Section: Introductionmentioning

confidence: 99%

Investigation of Manufacturing 316L Stainless Steel Closed Impeller Using Laser Powder Bed Fusion

Al Horr,

Alkhalaf

2024

Mater. Plus

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The manufacturing of closed impellers via Laser Powder Bed Fusion technology entails inherent complexities, demanding meticulous attention to support structure design, determination of building angle, and down-skin energy density to ensure successful production. This study explores the use of stainless steel 316L in fabricating closed impellers using LPBF. The aim is to investigate the impact of process parameters and building angles on impeller fabrication quality. In addition to studying the effect of energy density on the surface roughness and hardness values of the impeller. The investigation examines building angles of 0˚, 30˚, and 90˚ for a closed impeller, revealing that a 30˚ building angle yields successful printed parts. Moreover, to achieve defect-free closed impellers, it is imperative to maintain down-skin energy density between 80% and 100% of in-skin energy density. The maximum hardness and minimum surface roughness were recorded at 233 HV and 12.79 µm, respectively, when the energy density was 41.66 J/mm³ and 55.55 J/mm³ respectively. The novelty of this study lies in the fabrication of closed impellers using stainless steel 316L through laser powder bed fusion.

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Section: Introductionmentioning

confidence: 99%

Investigation of Manufacturing 316L Stainless Steel Closed Impeller Using Laser Powder Bed Fusion

Al Horr,

Alkhalaf

2024

Mater. Plus

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“…This research addresses the foregoing challenge by devising a mesh-free graph theory-based computational thermal modeling approach to predict the temperature distribution in DED parts. The graph theory approach has previously been published in the context of the laser powder bed fusion (LPBF) process (Yavari et al , 2019; Cole et al , 2020; Yavari et al , 2020; Gaikwad et al , 2020; Yavari et al , 2021a, 2021b, 2021c). The approach is verified to be five to ten times faster than FE modeling, enabling the prediction of thermal history using desktop computing in the context of the LPBF process. This paper develops, applies and validates the graph theory approach in the context of the DED process.…”

Section: Introductionmentioning

confidence: 99%

Thermal modeling of directed energy deposition additive manufacturing using graph theory

Riensche

Severson

Yavari

et al. 2022

RPJ

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Purpose The purpose of this paper is to develop, apply and validate a mesh-free graph theory–based approach for rapid thermal modeling of the directed energy deposition (DED) additive manufacturing (AM) process. Design/methodology/approach In this study, the authors develop a novel mesh-free graph theory–based approach to predict the thermal history of the DED process. Subsequently, the authors validated the graph theory predicted temperature trends using experimental temperature data for DED of titanium alloy parts (Ti-6Al-4V). Temperature trends were tracked by embedding thermocouples in the substrate. The DED process was simulated using the graph theory approach, and the thermal history predictions were validated based on the data from the thermocouples. Findings The temperature trends predicted by the graph theory approach have mean absolute percentage error of approximately 11% and root mean square error of 23°C when compared to the experimental data. Moreover, the graph theory simulation was obtained within 4 min using desktop computing resources, which is less than the build time of 25 min. By comparison, a finite element–based model required 136 min to converge to similar level of error. Research limitations/implications This study uses data from fixed thermocouples when printing thin-wall DED parts. In the future, the authors will incorporate infrared thermal camera data from large parts. Practical implications The DED process is particularly valuable for near-net shape manufacturing, repair and remanufacturing applications. However, DED parts are often afflicted with flaws, such as cracking and distortion. In DED, flaw formation is largely governed by the intensity and spatial distribution of heat in the part during the process, often referred to as the thermal history. Accordingly, fast and accurate thermal models to predict the thermal history are necessary to understand and preclude flaw formation. Originality/value This paper presents a new mesh-free computational thermal modeling approach based on graph theory (network science) and applies it to DED. The approach eschews the tedious and computationally demanding meshing aspect of finite element modeling and allows rapid simulation of the thermal history in additive manufacturing. Although the graph theory has been applied to thermal modeling of laser powder bed fusion (LPBF), there are distinct phenomenological differences between DED and LPBF that necessitate substantial modifications to the graph theory approach.

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“…Metal additive manufacturing (AM) is rapidly emerging as a new manufacturing process that allows for the fabrication of complex 3D objects of metal or alloys such as impellers, [1,2] turbine blades, [3,4] propellers, [5][6][7] and lattice structures. [8][9][10] The commonly used metal AM technique is based on arc plasma heat sources such as gas metal arc welding(GMAW) or gas tungsten arc welding(GTAW) and exhibits various advantages, including low manufacturing costs, high productivity, [11,12] and dissimilar deposition.…”

Section: Introductionmentioning

confidence: 99%

High‐Throughput Metal 3D Printing Pen Enabled by a Continuous Molten Droplet Transfer

et al. 2022

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In metal additive manufacturing (AM), arc plasma is attracting attention as an alternative heat source to expensive lasers to enable the use of various metal wire materials with a high deposition efficiency. However, the stepwise material deposition and resulting limited number of degrees of freedom limit their potential for high-throughput and large-scale production for industrial applications. Herein, a high-throughput metal 3D printing pen (M3DPen) strategy is proposed based on an arc plasma heat source by harnessing the surface tension of the molten metal for enabling continuous material deposition without a downward flow by gravity. The proposed approach differs from conventional arc-based metal AM in that it controls the solidification and cooling time between interlayers of a point-by-point deposition path, thereby allowing for continuous metal 3D printing of freestanding and overhanging structures at once. The resulting mechanical properties and unique microstructures by continuous metal deposition that occur due to the difference in the thermal conditions of the molten metal under cooling are also investigated. This technology can be applied to a wide range of alloy systems and industrial manufacturing, thereby providing new possibilities for metal 3D printing.

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Thermal modeling in metal additive manufacturing using graph theory – Application to laser powder bed fusion of a large volume impeller

Cited by 24 publications

References 38 publications

Investigation of Manufacturing 316L Stainless Steel Closed Impeller Using Laser Powder Bed Fusion

Investigation of Manufacturing 316L Stainless Steel Closed Impeller Using Laser Powder Bed Fusion

Thermal modeling of directed energy deposition additive manufacturing using graph theory

High‐Throughput Metal 3D Printing Pen Enabled by a Continuous Molten Droplet Transfer

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