An improved prediction of residual stresses and distortion in additive manufacturing

Mukherjee, T.; Zhang, W.; DebRoy, T.

doi:10.1016/j.commatsci.2016.10.003

Title: An improved prediction of residual stresses and distortion in additive manufacturing

Journal Article · Fri Oct 20 00:00:00 EDT 2017 · Computational Materials Science

DOI:https://doi.org/10.1016/j.commatsci.2016.10.003· OSTI ID:1533667

Mukherjee, T. ^[1]; Zhang, W. ^[2]; DebRoy, T. ^[1]

Pennsylvania State University, University Park, PA (United States)
The Ohio State University, Columbus, OH (United States)

In laser assisted additive manufacturing (AM) an accurate estimation of residual stresses and distortion is necessary to achieve dimensional accuracy and prevent premature fatigue failure, delamination and buckling of components. Since many process variables affect AM, experimental measurements of residual stresses and distortion are time consuming and expensive. Numerical thermo-mechanical models can be used for their estimation, but the quality of calculations depends critically on the accurate transient temperature field which affects both the residual stresses and distortion. Here in this study, a well-tested, three-dimensional, transient heat transfer and fluid flow model is used to accurately calculate transient temperature field for the residual stress and distortion modeling. The calculated residual stress distributions are compared with independent experimental results. It is shown that the residual stresses can be significantly minimized by reducing the layer thickness during AM. Inconel 718 components are found to be more susceptible to delamination than Ti-6Al-4V parts because they encounter higher residual stresses compared to their yield strength.

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Research Organization:: Pennsylvania State Univ., University Park, PA (United States)

Sponsoring Organization:: USDOE Office of Nuclear Energy (NE), Nuclear Energy University Program (NEUP); American Welding Society; USDOE

Grant/Contract Number:: NE0008280; 179466

OSTI ID:: 1533667

Alternate ID(s):: OSTI ID: 1397597

Journal Information:: Computational Materials Science, Vol. 126, Issue C; ISSN 0927-0256

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 409 works

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Assumption of Constraining Force to Explain Distortion in Laser Additive Manufacturing Xie, Deqiao; Zhao, Jianfeng; Liang, Huixin Materials, Vol. 11, Issue 11 https://doi.org/10.3390/ma11112327	journal	November 2018

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Title: An improved prediction of residual stresses and distortion in additive manufacturing

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