Simultaneous optimization of hatching orientations and lattice density distribution for residual warpage reduction in laser powder bed fusion considering layerwise residual stress stacking

Takezawa, Akihiro; Guo, Honghu; Kobayashi, Ryotaro; Chen, Qian; To, Albert C.

doi:10.1016/j.addma.2022.103194

Simultaneous optimization of hatching orientations and lattice density distribution for residual warpage reduction in laser powder bed fusion considering layerwise residual stress stacking

Journal Article · Thu Oct 13 00:00:00 EDT 2022 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2022.103194· OSTI ID:2418367

^[1]; Guo, Honghu ^[2]; Kobayashi, Ryotaro ^[2]; Chen, Qian ^[3]; ^[3]

Waseda Univ., Shinjuku (Japan); OSTI
Waseda Univ., Shinjuku (Japan)
Univ. of Pittsburgh, PA (United States)

The reduction in the residual warpage generated via fabrication is an emerging issue in metals’ laser powder bed fusion additive manufacturing (AM). One solution from a design for additive manufacturing (DfAM) perspective is to arrange a hatching strategy that utilizes the asymmetry of the residual stress generated from a molten pool. Another approach is to arrange the geometry of the parts, such as forming an inner lattice structure to arrange the effective stiffness. In this study, the simultaneous optimization of the laser hatching orientation and lattice density distribution was conducted to minimize the residual warpage in lattice infill structures and confirm their synergetic effect. The mutual effect of each layer was highlighted when considering the mechanical background of the optimal results because an imbalance in the residual stress caused the warpage of the AM parts between the layers. The proposed methodology was validated via experimental verification using a quasi-2D plate, 3D bracket, and 3D connecting-rod design problems. The residual warpage in the quasi-2D study, measured as the edge’s vertical deformation, was reduced from 23.4% to 39.4% compared with the benchmark design. In the 3D studies, the warpage reductions ranged from 13.1% to 20.7%.

View Accepted Manuscript (DOE)

Research Organization:: Univ. of Pittsburgh, PA (United States)

Sponsoring Organization:: USDOE Office of Nuclear Energy (NE)

Grant/Contract Number:: NE0008994

OSTI ID:: 2418367

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: Part A Vol. 60; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (32)

Simulation of multipass welding of a thick plate Lindgren, Lars-Erik; Runnemalm, Henrik; N�sstr�m, Mats O. International Journal for Numerical Methods in Engineering, Vol. 44, Issue 9 https://doi.org/10.1002/(SICI)1097-0207(19990330)44:9<1301::AID-NME479>3.0.CO;2-K	journal	March 1999
The method of moving asymptotes—a new method for structural optimization Svanberg, Krister International Journal for Numerical Methods in Engineering, Vol. 24, Issue 2 https://doi.org/10.1002/nme.1620240207	journal	February 1987
Evaluation of the impact of scanning strategies on residual stresses in selective laser melting Mugwagwa, L.; Dimitrov, D.; Matope, S. The International Journal of Advanced Manufacturing Technology, Vol. 102, Issue 5-8 https://doi.org/10.1007/s00170-019-03396-9	journal	February 2019
Development of a simulation approach for laser powder bed fusion based on scanning strategy selection Foteinopoulos, Panagis; Papacharalampopoulos, Alexios; Angelopoulos, Konstantinos The International Journal of Advanced Manufacturing Technology, Vol. 108, Issue 9-10 https://doi.org/10.1007/s00170-020-05603-4	journal	June 2020
Topology optimization parallel-computing framework based on the inherent strain method for support structure design in laser powder-bed fusion additive manufacturing Zhang, Zhi-Dong; Ibhadode, Osezua; Ali, Usman International Journal of Mechanics and Materials in Design, Vol. 16, Issue 4 https://doi.org/10.1007/s10999-020-09494-x	journal	April 2020
Metal Additive Manufacturing: A Review Frazier, William E. Journal of Materials Engineering and Performance, Vol. 23, Issue 6 https://doi.org/10.1007/s11665-014-0958-z	journal	April 2014
Investigations on residual stresses and deformations in selective laser melting Zaeh, Michael F.; Branner, Gregor Production Engineering, Vol. 4, Issue 1 https://doi.org/10.1007/s11740-009-0192-y	journal	November 2009
Preprocessing and postprocessing for materials based on the homogenization method with adaptive finite element methods Guedes, JoséMiranda; Kikuchi, Noboru Computer Methods in Applied Mechanics and Engineering, Vol. 83, Issue 2 https://doi.org/10.1016/0045-7825(90)90148-F	journal	October 1990
Build direction dependence of microstructure and high-temperature tensile property of Co–Cr–Mo alloy fabricated by electron beam melting Sun, Shi-Hai; Koizumi, Yuichiro; Kurosu, Shingo Acta Materialia, Vol. 64 https://doi.org/10.1016/j.actamat.2013.10.017	journal	February 2014
Additive manufacturing of metals Herzog, Dirk; Seyda, Vanessa; Wycisk, Eric Acta Materialia, Vol. 117 https://doi.org/10.1016/j.actamat.2016.07.019	journal	September 2016
Empirical methodology to determine inherent strains in additive manufacturing Setien, Iñaki; Chiumenti, Michele; van der Veen, Sjoerd Computers & Mathematics with Applications, Vol. 78, Issue 7 https://doi.org/10.1016/j.camwa.2018.05.015	journal	October 2019
Coupled thermo-mechanical process simulation method for selective laser melting considering phase transformation steels Schänzel, Michael; Shakirov, Damir; Ilin, Alexander Computers & Mathematics with Applications, Vol. 78, Issue 7 https://doi.org/10.1016/j.camwa.2019.01.019	journal	October 2019
Sensitivity analysis and lattice density optimization for sequential inherent strain method used in additive manufacturing process Takezawa, Akihiro; To, Albert C.; Chen, Qian Computer Methods in Applied Mechanics and Engineering, Vol. 370 https://doi.org/10.1016/j.cma.2020.113231	journal	October 2020
Topology Optimization for additive manufacturing with distortion constraints Misiun, Grzegorz; van de Ven, Emiel; Langelaar, Matthijs Computer Methods in Applied Mechanics and Engineering, Vol. 386 https://doi.org/10.1016/j.cma.2021.114095	journal	December 2021
Residual stress constrained self-support topology optimization for metal additive manufacturing Xu, Shuzhi; Liu, Jikai; Ma, Yongsheng Computer Methods in Applied Mechanics and Engineering, Vol. 389 https://doi.org/10.1016/j.cma.2021.114380	journal	February 2022
How to determine composite material properties using numerical homogenization Andreassen, Erik; Andreasen, Casper Schousboe Computational Materials Science, Vol. 83 https://doi.org/10.1016/j.commatsci.2013.09.006	journal	February 2014
Size effect in selective laser melting additive manufacturing of 700 mm large component Jia, Haolin; Sun, Hua; Wang, Hongze Journal of Manufacturing Processes, Vol. 75 https://doi.org/10.1016/j.jmapro.2022.01.011	journal	March 2022
Bio-inspired lattice structure optimisation with strain trajectory aligned trusses Daynes, Stephen; Feih, Stefanie Materials & Design, Vol. 213 https://doi.org/10.1016/j.matdes.2021.110320	journal	January 2022
In-situ residual stress reduction, martensitic decomposition and mechanical properties enhancement through high temperature powder bed pre-heating of Selective Laser Melted Ti6Al4V Ali, Haider; Ma, Le; Ghadbeigi, Hassan Materials Science and Engineering: A, Vol. 695 https://doi.org/10.1016/j.msea.2017.04.033	journal	May 2017
Study on the microstructure, mechanical property and residual stress of SLM Inconel-718 alloy manufactured by differing island scanning strategy Lu, Yanjin; Wu, Songquan; Gan, Yiliang Optics & Laser Technology, Vol. 75 https://doi.org/10.1016/j.optlastec.2015.07.009	journal	December 2015
Review on residual stress in selective laser melting additive manufacturing of alloy parts Fang, Ze-Chen; Wu, Zhi-Lin; Huang, Chen-Guang Optics & Laser Technology, Vol. 129 https://doi.org/10.1016/j.optlastec.2020.106283	journal	September 2020
Mechanical Performance of Lightweight-Designed Honeycomb Structures Fabricated Using Multijet Fusion Additive Manufacturing Technology Nazir, Aamer; Arshad, Ahmad Bin; Lin, Shang-Chih 3D Printing and Additive Manufacturing, Vol. 9, Issue 4 https://doi.org/10.1089/3dp.2021.0004	journal	August 2022
Efficient design optimization of variable-density cellular structures for additive manufacturing: theory and experimental validation Cheng, Lin; Zhang, Pu; Biyikli, Emre Rapid Prototyping Journal, Vol. 23, Issue 4 https://doi.org/10.1108/RPJ-04-2016-0069	journal	June 2017
Prediction of Residual Stresses in Butt Welded Plates Using Inherent Strains Ueda, Y.; Yuan, M. G. Journal of Engineering Materials and Technology, Vol. 115, Issue 4 https://doi.org/10.1115/1.2904240	journal	October 1993
A Finite-Element Model for Residual Stresses and Deflections in Girth-Butt Welded Pipes Rybicki, E. F.; Schmueser, D. W.; Stonesifer, R. W. Journal of Pressure Vessel Technology, Vol. 100, Issue 3 https://doi.org/10.1115/1.3454464	journal	August 1978
Efficient Design-Optimization of Variable-Density Hexagonal Cellular Structure by Additive Manufacturing: Theory and Validation Zhang, Pu; Toman, Jakub; Yu, Yiqi Journal of Manufacturing Science and Engineering, Vol. 137, Issue 2 https://doi.org/10.1115/1.4028724	journal	April 2015
Hybrid Processes in Additive Manufacturing Sealy, Michael P.; Madireddy, Gurucharan; Williams, Robert E. Journal of Manufacturing Science and Engineering, Vol. 140, Issue 6 https://doi.org/10.1115/1.4038644	journal	March 2018
Assessing and comparing influencing factors of residual stresses in selective laser melting using a novel analysis method Kruth, Jean-Pierre; Deckers, Jan; Yasa, Evren Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 226, Issue 6 https://doi.org/10.1177/0954405412437085	journal	February 2012
Residual stress and distortion modeling of electron beam direct manufacturing Ti-6Al-4V Denlinger, Erik R.; Heigel, Jarred C.; Michaleris, Panagiotis Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 229, Issue 10 https://doi.org/10.1177/0954405414539494	journal	July 2014
Review on powder-bed laser additive manufacturing of Inconel 718 parts Wang, Xiaoqing; Gong, Xibing; Chou, Kevin Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 231, Issue 11 https://doi.org/10.1177/0954405415619883	journal	January 2016
Dynamic Young's Modulus Measurements in Metallic Materials: Results of an Interlaboratory Testing Program Wolfenden, A.; Harmouche, Mr; Blessing, Gv Journal of Testing and Evaluation, Vol. 17, Issue 1 https://doi.org/10.1520/JTE11527J	journal	January 1989
Investigation on reducing distortion by preheating during manufacture of aluminum components using selective laser melting Buchbinder, Damien; Meiners, Wilhelm; Pirch, Norbert Journal of Laser Applications, Vol. 26, Issue 1 https://doi.org/10.2351/1.4828755	journal	February 2014

Similar Records

Finite Element Analysis of Warpage in Laminated Aluminium Alloy Plates for Machining of Primary Aeronautic Parts

Journal Article · Sat Apr 07 00:00:00 EDT 2007 · AIP Conference Proceedings · OSTI ID:21056994

Reducing warpage in a hybrid large-scale additive manufacturing and compression molding process

Conference · Sun Oct 01 00:00:00 EDT 2023 · OSTI ID:2283866

Effect of Internal Structure on Warpage in a Large-Scale Additive Manufacturing Process With Bio-Derived Composites

Conference · Wed Jan 31 23:00:00 EST 2024 · OSTI ID:2406816

Related Subjects

36 MATERIALS SCIENCE
design optimization
inherent strain method
residual deformation
scanning strategy
variable lattice density

Simultaneous optimization of hatching orientations and lattice density distribution for residual warpage reduction in laser powder bed fusion considering layerwise residual stress stacking

Citation Formats

References (32)

Similar Records

Related Subjects