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Title: Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire

Abstract

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180° rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.

Authors:
ORCiD logo; ; ; ; ;
Publication Date:
Sponsoring Org.:
USDOE
OSTI Identifier:
1575834
Grant/Contract Number:  
NFE-15-05725
Resource Type:
Published Article
Journal Name:
Applied Sciences
Additional Journal Information:
Journal Name: Applied Sciences Journal Volume: 9 Journal Issue: 23; Journal ID: ISSN 2076-3417
Publisher:
MDPI AG
Country of Publication:
Switzerland
Language:
English

Citation Formats

Lee, Yousub, Bandari, Yashwanth, Nandwana, Peeyush, Gibson, Brian. T., Richardson, Brad, and Simunovic, Srdjan. Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire. Switzerland: N. p., 2019. Web. doi:10.3390/app9235115.
Lee, Yousub, Bandari, Yashwanth, Nandwana, Peeyush, Gibson, Brian. T., Richardson, Brad, & Simunovic, Srdjan. Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire. Switzerland. doi:10.3390/app9235115.
Lee, Yousub, Bandari, Yashwanth, Nandwana, Peeyush, Gibson, Brian. T., Richardson, Brad, and Simunovic, Srdjan. Tue . "Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire". Switzerland. doi:10.3390/app9235115.
@article{osti_1575834,
title = {Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire},
author = {Lee, Yousub and Bandari, Yashwanth and Nandwana, Peeyush and Gibson, Brian. T. and Richardson, Brad and Simunovic, Srdjan},
abstractNote = {Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180° rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.},
doi = {10.3390/app9235115},
journal = {Applied Sciences},
number = 23,
volume = 9,
place = {Switzerland},
year = {2019},
month = {11}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
DOI: 10.3390/app9235115

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