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

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).
Authors:
 [1] ;  [1] ;  [1] ;  [1] ;  [2] ;  [3] ;  [1] ;  [1] ;  [2]
  1. Sandia National Lab. (SNL-CA), Livermore, CA (United States)
  2. Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
  3. Univ. of California, Davis, CA (United States)
Publication Date:
Report Number(s):
SAND-2018-4115J
Journal ID: ISSN 2214-8604; 672198
Grant/Contract Number:
AC04-94AL85000
Type:
Accepted Manuscript
Journal Name:
Additive Manufacturing
Additional Journal Information:
Journal Volume: 21; Journal Issue: C; Journal ID: ISSN 2214-8604
Publisher:
Elsevier
Research Org:
Sandia National Lab. (SNL-CA), Livermore, CA (United States); Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Sponsoring Org:
USDOE National Nuclear Security Administration (NNSA)
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING
OSTI Identifier:
1496979

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., and Dagel, Daryl J.. A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling. United States: N. p., Web. doi:10.1016/j.addma.2018.04.012.
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.. A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling. United States. doi:10.1016/j.addma.2018.04.012.
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., and Dagel, Daryl J.. 2018. "A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling". United States. doi:10.1016/j.addma.2018.04.012.
@article{osti_1496979,
title = {A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling},
author = {Stender, Michael E. and Beghini, Lauren L. and Sugar, Joshua D. and Veilleux, Michael G. and Subia, Samuel R. and Smith, Thale R. and Marchi, Christopher W. San and Brown, Arthur A. and Dagel, Daryl J.},
abstractNote = {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).},
doi = {10.1016/j.addma.2018.04.012},
journal = {Additive Manufacturing},
number = C,
volume = 21,
place = {United States},
year = {2018},
month = {5}
}