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

Abstract

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 differentmore » stages of the EBM process.« less

Authors:
ORCiD logo [1];  [2];  [3];  [4]
  1. Univ. of Texas, El Paso, TX (United States)
  2. Texas A & M Univ., College Station, TX (United States)
  3. Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility
  4. Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)
Sponsoring Org.:
USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
OSTI Identifier:
1357959
Alternate Identifier(s):
OSTI ID: 1356673
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Additive Manufacturing
Additional Journal Information:
Journal Volume: 7; Journal Issue: C; Journal ID: ISSN 2214-8604
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
97 MATHEMATICS AND COMPUTING

Citation Formats

Prabhakar, P., Sames, William J., Dehoff, Ryan R., and Babu, Sudarsanam Suresh. Computational modeling of residual stress formation during the electron beam melting process for Inconel 718. United States: N. p., 2015. Web. doi:10.1016/j.addma.2015.03.003.
Prabhakar, P., Sames, William J., Dehoff, Ryan R., & Babu, Sudarsanam Suresh. Computational modeling of residual stress formation during the electron beam melting process for Inconel 718. United States. doi:10.1016/j.addma.2015.03.003.
Prabhakar, P., Sames, William J., Dehoff, Ryan R., and Babu, Sudarsanam Suresh. Sat . "Computational modeling of residual stress formation during the electron beam melting process for Inconel 718". United States. doi:10.1016/j.addma.2015.03.003. https://www.osti.gov/servlets/purl/1357959.
@article{osti_1357959,
title = {Computational modeling of residual stress formation during the electron beam melting process for Inconel 718},
author = {Prabhakar, P. and Sames, William J. and Dehoff, Ryan R. and Babu, Sudarsanam Suresh},
abstractNote = {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.},
doi = {10.1016/j.addma.2015.03.003},
journal = {Additive Manufacturing},
number = C,
volume = 7,
place = {United States},
year = {Sat Mar 28 00:00:00 EDT 2015},
month = {Sat Mar 28 00:00:00 EDT 2015}
}

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Cited by: 22 works
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