Thermo-mechanical analysis in pulsed laser cladding of WC powder on Inconel 718

Javid, Youness; Ghoreishi, M.

doi:10.1007/s00170-017-0117-4

Cited by 36 publications

(6 citation statements)

References 19 publications

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“…In the boundary conditions, thermal conductivity normal to the surface, thermal radiation and convection, and boundary heat flux of laser beam can be described by Eq. ( 2) [19],…”

Section: Governing Equationsmentioning

confidence: 99%

Research on the temperature control strategy of thin-wall parts fabricated by laser direct metal deposition

Chen

Liu

et al. 2022

Int J Adv Manuf Technol

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To solve the problem that the macro-size, microhardness, and mechanical properties of the laser direct metal deposition (DMD) of thin-walled parts are inconsistent due to the heat accumulation, an improved three-dimensional finite element heat propagation model was developed to simulate the temperature evolution of the single-pass multi-layer thin-walled parts.The results show that the heat accumulation is contributed to the transformation of the heat dissipation mechanism from three-dimensional to two-dimensional, while the residual heat of the former layer has no significant effect on the heat accumulation of the current layer. The optimized strategy of decreasing laser power gradually is more effective than the optimized strategy of increasing the time interval between layers in maintaining the stability of the molten pool. The integrated optimized strategy of parabolic-shape laser power decreasing and time interval of 5 s is the most effective method to reduce the heat accumulation in the DMD of thinwalled parts. The thin-walled parts with an optimized deposition process have a more uniform width, finer microstructure, and higher microhardness. This work provides theoretical guidance for reducing the heat accumulation during DMD thin-walled parts and is beneficial to improving the uniformity of mechanical properties of thin-walled parts.

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“…In the boundary conditions, thermal conductivity normal to the surface, thermal radiation and convection, and boundary heat flux of laser beam can be described by Eq. ( 2) [19],…”

Section: Governing Equationsmentioning

confidence: 99%

Research on the temperature control strategy of thin-wall parts fabricated by laser direct metal deposition

Chen

Liu

et al. 2022

Int J Adv Manuf Technol

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“…The main models used to describe laser heat source include Rosonthal analytical model, Gauss distribution heat source model, uniform heat source model, semispherical heat source model, ellipsoidal model and double-ellipsoid heat source model [37][38][39][40][41][42][43][44][45][46][47][48][49][50], etc. As for laser cladding, diffractive optical element is usually used to transform Gauss beam into rectangular beam with uniform energy density distribution [51], so the uniform heat source model is usually applied in numerical simulation.…”

Section: Thermal-mechanical Coupling Finite Element Modelingmentioning

confidence: 99%

Numerical Simulation of Convex Shape Beam Spot on Stress Field of Plasma-sprayed MCrAlY Coating During Laser Cladding Process

Zhang

Chu

et al. 2021

Preprint

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In order to reduce the thermal stress at clad layer and further reduce the crack generation in the laser cladding process, a method of controlling the cracks at clad layer by changing the laser energy density was proposed. The comparative thermal-mechanical coupling finite element analysis was conducted for the uniform rectangular spot and convex shape beam spot cladding processes on plasma-sprayed MCrAlY coating through the numerical simulation method based on the ANSYS software. The results show that the rapid heating and cooling characteristics, which are typical in laser processing, are manifested in the cladding process using the uniform rectangular spot, and the convex shape spot can exert the preheating and slow cooling effects to a certain extent, so as to reduce the temperature gradient of the cladding zone and non-cladding zone. In addition, on the precondition of equivalent cladding effect, the thermal stress at the clad layer is also low, so the cracking tendency of the clad layer can be effectively mitigated. Relative to the laser beam shaped diffractive optical element special for design and manufacturing, superposing two uniform rectangular spots with different sizes and energy densities is a simpler and more effective method of acquiring the convex shape spot.

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“…Laser Powder Bed Fusion (LPBF) is one of the most promising AM technologies and can be directly used to fabricate metal components with high precision and performance for various industries such as aerospace, biomedical, defence, and automotive [1,4]. In LPBF, a laser beam selectively melts the powder in a powder bed, several melting tracks are strung together in a micro-welding process, and a 3D component is created inside the powder Materials 2023, 16, 7164 2 of 27 envelope where several of these layers are fused together [5]. Various materials can be used in LPBF, such as aluminium, copper, nickel, and titanium, while the mechanical properties of the produced parts can be similar to or even better than those of parts manufactured via traditional methods, such as machining and moulding [1,5].…”

Section: Introductionmentioning

confidence: 99%

“…It was found that changing from the initial solid elements to powder elements results in higher temperature gradients, larger transient and residual stresses, and increased warpage. Javid and Ghoreishi [16] analysed the thermal deformation behaviour of Inconel 718 alloy during LPFB using TMA. It was found that the deformation behaviour was related to the micro-structure of the material and was influenced by the heating rate.…”

Section: Introductionmentioning

confidence: 99%

Support Structures Optimisation for High-Quality Metal Additive Manufacturing with Laser Powder Bed Fusion: A Numerical Simulation Study

Dimopoulos,

Salimi,

Gan

et al. 2023

Materials

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This study focuses on Metal Additive Manufacturing (AM), an emerging method known for its ability to create lightweight components and intricate designs. However, Laser Powder Bed Fusion (LPBF), a prominent AM technique, faces a major challenge due to the development of high residual stress, resulting in flawed parts and printing failures. The study’s goal was to assess the thermal behaviour of different support structures and optimised designs to reduce the support volume and residual stress while ensuring high-quality prints. To explore this, L-shaped specimens were printed using block-type support structures through an LPBF machine. This process was subsequently validated through numerical simulations, which were in alignment with experimental observations. In addition to block-type support structures, line, contour, and cone supports were examined numerically to identify the optimal solutions that minimise the support volume and residual stress while maintaining high-quality prints. The optimisation approach was based on the Design of Experiments (DOE) methodology and multi-objective optimisation. The findings revealed that block supports exhibited excellent thermal behaviour. High-density supports outperformed low-density alternatives in temperature distribution, while cone-type supports were more susceptible to warping. These insights provide valuable guidance for improving the metal AM and LPBF processes, enabling their broader use in industries like aerospace, medical, defence, and automotive.

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Thermo-mechanical analysis in pulsed laser cladding of WC powder on Inconel 718

Cited by 36 publications

References 19 publications

Research on the temperature control strategy of thin-wall parts fabricated by laser direct metal deposition

Research on the temperature control strategy of thin-wall parts fabricated by laser direct metal deposition

Numerical Simulation of Convex Shape Beam Spot on Stress Field of Plasma-sprayed MCrAlY Coating During Laser Cladding Process

Support Structures Optimisation for High-Quality Metal Additive Manufacturing with Laser Powder Bed Fusion: A Numerical Simulation Study

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Thermo-mechanical analysis in pulsed laser cladding of WC powder on Inconel 718

Cited by 36 publications

References 19 publications

Research on the temperature control strategy of thin-wall parts fabricated by laser direct metal deposition

Research on the temperature control strategy of thin-wall parts fabricated by laser direct metal deposition

Numerical Simulation of Convex Shape Beam Spot on Stress Field of Plasma-sprayed MCrAlY&nbsp;Coating During Laser Cladding Process

Support Structures Optimisation for High-Quality Metal Additive Manufacturing with Laser Powder Bed Fusion: A Numerical Simulation Study

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Numerical Simulation of Convex Shape Beam Spot on Stress Field of Plasma-sprayed MCrAlY Coating During Laser Cladding Process