Computational modeling of residual stress formation during the electron beam melting process for Inconel 718

Prabhakar, P.; Sames, William J.; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

doi:10.1016/j.addma.2015.03.003

Title: Computational modeling of residual stress formation during the electron beam melting process for Inconel 718

Journal Article · Sat Mar 28 00:00:00 EDT 2015 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2015.03.003· OSTI ID:1357959

^[1]; Sames, William J. ^[2]; Dehoff, Ryan R. ^[3]; Babu, Sudarsanam Suresh ^[4]

Univ. of Texas, El Paso, TX (United States)
Texas A & M Univ., College Station, TX (United States)
Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility
Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility

Here, a computational modeling approach to simulate residual stress formation during the electron beam melting (EBM) process within the additive manufacturing (AM) technologies for Inconel 718 is presented in this paper. The EBM process has demonstrated a high potential to fabricate components with complex geometries, but the resulting components are influenced by the thermal cycles observed during the manufacturing process. When processing nickel based superalloys, very high temperatures (approx. 1000 °C) are observed in the powder bed, base plate, and build. These high temperatures, when combined with substrate adherence, can result in warping of the base plate and affect the final component by causing defects. It is important to have an understanding of the thermo-mechanical response of the entire system, that is, its mechanical behavior towards thermal loading occurring during the EBM process prior to manufacturing a component. Therefore, computational models to predict the response of the system during the EBM process will aid in eliminating the undesired process conditions, a priori, in order to fabricate the optimum component. Such a comprehensive computational modeling approach is demonstrated to analyze warping of the base plate, stress and plastic strain accumulation within the material, and thermal cycles in the system during different stages of the EBM process.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)

Sponsoring Organization:: USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1357959

Alternate ID(s):: OSTI ID: 1356673

Journal Information:: Additive Manufacturing, Vol. 7, Issue C; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 127 works

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