A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling

Stender, Michael E.; Beghini, Lauren L.; Sugar, Joshua D.; Veilleux, Michael G.; Subia, Samuel R.; Smith, Thale R.; Marchi, Christopher W.  San; Brown, Arthur A.; Dagel, Daryl J.

doi:10.1016/j.addma.2018.04.012

A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling

Journal Article · Tue May 01 00:00:00 EDT 2018 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2018.04.012· OSTI ID:1496979

Stender, Michael E. ^[1]; Beghini, Lauren L. ^[1]; Sugar, Joshua D. ^[1]; Veilleux, Michael G. ^[1]; Subia, Samuel R. ^[2]; Smith, Thale R. ^[3]; Marchi, Christopher W. San ^[1]; Brown, Arthur A. ^[1]; Dagel, Daryl J. ^[2]

Sandia National Lab. (SNL-CA), Livermore, CA (United States)
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Univ. of California, Davis, CA (United States)

This work proposes a finite element (FE) analysis workflow to simulate directed energy deposition (DED) additive manufacturing at a macroscopic length scale (i.e. part length scale) and to predict thermal conditions during manufacturing, as well as distortions, strength and residual stresses at the completion of manufacturing. The proposed analysis method incorporates a multi-step FE workflow to elucidate the thermal and mechanical responses in laser engineered net shaping (LENS) manufacturing. For each time step, a thermal element activation scheme captures the material deposition process. Then, activated elements and their associated geometry are analyzed first thermally for heat flow due to radiation, convection, and conduction, and then mechanically for the resulting stresses, displacements, and material property evolution. Finally, simulations agree with experimentally measured in situ thermal measurements for simple cylindrical build geometries, as well as general trends of local hardness distribution and plastic strain accumulation (represented by relative distribution of geometrically necessary dislocations).

View Accepted Manuscript (DOE)

Research Organization:: Sandia National Laboratories (SNL-CA), Livermore, CA (United States); Sandia National Laboratories, Albuquerque, NM

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC04-94AL85000

OSTI ID:: 1496979

Report Number(s):: SAND--2018-4115J; 672198

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: C Vol. 21; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy Karlson, Kyle N.; Alleman, Coleman; Foulk III, James W. International Journal of Fracture, Vol. 218, Issue 1-2 https://doi.org/10.1007/s10704-019-00365-x	journal	July 2019
In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing Wolff, Sarah J.; Wu, Hao; Parab, Niranjan Scientific Reports, Vol. 9, Issue 1 https://doi.org/10.1038/s41598-018-36678-5	journal	January 2019
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