What is it about?
A computational modeling framework was developed to predict residual stress and distortion of components built using laser powder bed fusion additive manufacturing (AM). The framework first initiates a thermal finite element analysis to predict the thermal history during the AM build process. Then, the resulting thermal histories drive a stress finite element analysis to predict residual stress and distortion. This work demonstrates that the computational framework provides distortion predictions that fall within the range of experimental measurements of Ti-6Al-4V specimens built with a Renishaw AM250 machine.
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Why is it important?
The layer-by-layer deposition of material during an additive manufacturing process produces severe thermal gradients and cooling rates that are different from traditional manufacturing processes and lead to residual stress and distortion. By predicting residual stress and distortion with a computation model, as we have demonstrated in this paper, these (and other) quantities may be tailored in the AM process based on performance requirements.
Perspectives
We hope this article encourages and supports researchers and manufacturers who are exploring metal additive manufacturing (AM) and the vast opportunities enabled by this technology. Our aim is to develop computational models and tools to help elucidate the complex metal AM process and support the community in realizing the full potential of this disruptive technology.
Matthew Kirby
Southwest Research Institute
Read the Original
This page is a summary of: An Additive Manufacturing Process Model for Powder-Bed Fusion: Implementation and Predictive Capability, January 2024, American Institute of Aeronautics and Astronautics (AIAA),
DOI: 10.2514/6.2024-2074.
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