Estimation of clad geometry and corresponding residual stress distribution in laser melting deposition: analytical modeling and experimental correlations

Author:

Mahmood Muhammad Arif,Popescu Andrei C.,Hapenciuc Claudiu Liviu,Ristoscu Carmen,Visan Anita Ioana,Oane Mihai,Mihailescu Ion N.

Abstract

AbstractLaser melting deposition (LMD) is a promising technology to produce net-shape parts. The deposited layers' characteristics and induced residual stress distribution influence the quality, mechanical, and physical properties of the manufactured parts. In this study, two theoretical models are presented. Initially, the clad geometry of the 1st deposited layer is estimated using the primary process parameters. Then, a hatch distance is used to calculate the re-melting depth and total clad geometry for all the deposited layers. The output of the 1st model is then used as an input in the 2nd model to estimate the residual stress distribution within the substrate and deposited layers. The model, for clad geometry, is validated using published experimental data for the depositions of AISI316L powder debits on AISI321 bulk substrate by the LMD process. For the residual stress distribution model validation, the published experimental results for X-ray diffractometry, in case of AISI4340 steel powder debits depositions on the AISI4140 bulk substrate by the LMD setup, are used. It was found that the current models can estimate the clad geometry and induced residual stress distribution with an accuracy of 10–15 % mean absolute deviation. An optimum selection of hatch distance is necessary for proper energy density utilization and dimensional control stability. The induced residual stress distribution was caused by the heating and cooling mechanisms, which appeared due to rapid heating and moderate cooling, in combination with slow conduction. These phenomena became incrementally iterative with the number of layers to be deposited, thus presenting a direct relationship between the residual stress distribution and the number of layers deposited on the substrate. The proposed models have high computational efficiency without restoring the meshing and iterative calculations. The high prediction accuracy and computational efficiency allow the presented model to investigate further the part distortion, part porosity, life-expectancy and mechanical properties of the part, and process parameter planning.

Funder

H2020 Marie Skłodowska-Curie Actions

Ministerul Educației și Cercetării Științifice

Unitatea Executiva pentru Finantarea Invatamantului Superior, a Cercetarii, Dezvoltarii si Inovarii

Publisher

Springer Science and Business Media LLC

Subject

Industrial and Manufacturing Engineering,Computer Science Applications,Mechanical Engineering,Software,Control and Systems Engineering

同舟云学术

1.学者识别学者识别

2.学术分析学术分析

3.人才评估人才评估

"同舟云学术"是以全球学者为主线,采集、加工和组织学术论文而形成的新型学术文献查询和分析系统,可以对全球学者进行文献检索和人才价值评估。用户可以通过关注某些学科领域的顶尖人物而持续追踪该领域的学科进展和研究前沿。经过近期的数据扩容,当前同舟云学术共收录了国内外主流学术期刊6万余种,收集的期刊论文及会议论文总量共计约1.5亿篇,并以每天添加12000余篇中外论文的速度递增。我们也可以为用户提供个性化、定制化的学者数据。欢迎来电咨询!咨询电话:010-8811{复制后删除}0370

www.globalauthorid.com

TOP

Copyright © 2019-2024 北京同舟云网络信息技术有限公司
京公网安备11010802033243号  京ICP备18003416号-3