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From Melt Pool to Microstructure to Mechanical Properties: A Simulative Approach to L-PBF Processed Material Behaviour

Vom Schmelzbad zur Mikrostruktur zu den mechanischen Eigenschaften: Ein simulationsbasierter Ansatz zur Berechnung von LPBF prozessierten Material Eigenschaften

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Abstract

An important goal for the additive manufacturing (AM) community is to predict the material-dependent effective mechanical properties of a build-up specimen. In this work three coupled simulations to calculate the mechanical properties of laser-power bed fusion (L-PBF) processed IN718 are used. These values are compared to experimental data from literature. In the future, this approach is going be used for newly designed materials to estimate the expected mechanical properties and the resulting microstructure (As an extra step, the thermophysical properties of the new alloy have to be calculated in advance). The simulation chain to solve this challenge involves the simulation of the melt pool behaviour during the L‑PBF process to obtain the solidification conditions. These are required to then calculate the microstructural growth behaviour with the phase-field method. The resulting microstructure is homogenized to obtain the final effective mechanical properties of the L‑PBF processed material. The simulation results are compared with according results from experiments at each step to verify the approach and each simulation result.

Zusammenfassung

Ein wichtiges Ziel im Bereich der Additiven Fertigung (AM) ist die Vorhersage der effektiven mechanischen Eigenschaften der gefertigten Bauteile.

In dieser Arbeit wird eine dreigliedrige Simulationskette vorgestellt. mit deren Hilfe die mechanischen Eigenschaften von mittles Laser Powder Bed Fusion (LPBF) bearbeitetem Inconel718 vorhergesagt und mit Literaturewerten verglichen werden. Zukünftig soll der präsentierte Ansatz dazu dienen neue, bisher noch nicht additiv verarbeitete/qualifizierte Materialien vorab zu untersuchen und Aussagen über die entstehende Mikrostruktur und die zu erwartenden mechanischen Eigenschaften zu treffen. (Für unbekannte Materialen müssen die thermophysikalischen Eigenschafte vorab noch berechnet werden, z. B. mit ThermoCalc).

Die erste Simulation löst das thermische Problem beim LPBF, und das Ergebnis sind die örtlich- und zeitlich aufgelösten Erstarrungsbedingungen, welche wiederum eine Eingangsgröße für die zweite Simulation sind. Bei dieser wird mittels der Phasenfeldmethode die Erstarrungsphase aufgelöst nachmodelliert, um eine 3D Mikrostruktur zu erhalten. Im dritten Schritt wird diese homogenisiert, und aus den Phaseneigeschaften werden die mechanischen Eigenschaften des LPBF prozessierten IN718 berechnet. Jeder Simulationsschritt wird anhand von experimentell gewonnenen Daten überprüft.

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Acknowledgements

We acknowledge funding by the German Federal Ministry of Education and Research in the framework of the “Forschungscampus Digital Photonic Production: DPP Direct,” FKZ Grant No. 13N13709.

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Authors and Affiliations

  1. Digital Additive Production DAP, RWTH Aachen University, University, Germany

    Jonas Zielinski M.Sc. &  Johannes Henrich Schleifenbaum

  2. Access e.V., Intzestraße 5, 52072 Aachen, Germany

    Guillaume Boussinot,  Gottfried Laschet &  Markus Apel

  3. Fraunhofer Institute for Laser Technology ILT, Steinbachstr 15, 52074 Aachen, Germany

    Johannes Henrich Schleifenbaum

  4. Campus Boulevard 73, 52074, Aachen, Germany

    Jonas Zielinski M.Sc.

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  1. Jonas Zielinski M.Sc.
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  2. Guillaume Boussinot
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  3. Gottfried Laschet
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  4. Markus Apel
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  5. Johannes Henrich Schleifenbaum
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Correspondence to Jonas Zielinski M.Sc..

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Zielinski, J., Boussinot, G., Laschet, G. et al. From Melt Pool to Microstructure to Mechanical Properties: A Simulative Approach to L-PBF Processed Material Behaviour. Berg Huettenmaenn Monatsh 165, 175–180 (2020). https://doi.org/10.1007/s00501-020-00965-4

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  • DOI: https://doi.org/10.1007/s00501-020-00965-4

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