Skip to main content
SpringerLink
Log in

Numerical studies of residual states and scaling effects in laser-directed energy deposition additive manufacturing

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Sequentially coupled thermo-mechanical model was used to simulate the residual stresses and residual distortions in the directed energy deposition additive manufacturing by laser. The proposed models were validated by comparison with experimental data. Different sizes of components were used to study the scaling effects. Results indicate that the residual stress can be controlled by the component sizes. This phenomenon can be explained by the bending deformation and the temperature fluctuations, especially the cooling rate, in the directed energy deposition additive manufacturing process. Both the bending deformation and the temperature fluctuations can be controlled by the ambient temperature and the designed process parameters. Analytical model was established to show how the components’ sizes affect the final residual states in combination with different design parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

References

  1. Yang QC, Zhang P, Cheng L, Zhang M, Chyu M, To AC (2016) Finite element modeling and validation of thermomechanical behavior of Ti-6Al-4V in directed energy deposition additive manufacturing. Addit Manuf 12:169–177

    Google Scholar 

  2. Ghasri-Khouzani M, Peng H, Rogge R, Attardo R, Ostiguy P, Neidig J, Billo R, Hoelale D, Shankar MR (2017) Experimental measurement of residual stress and distortion in additively manufactured stainless steel components with various dimensions. Mater Sci Eng A 707:689–700

    Article  Google Scholar 

  3. Flores J, Garmendia I, Pujana J (2019) Toolpath generation for the manufacture of metallic components by means of the laser metal deposition technique. Int J Adv Manuf Technol 101:2111–2120

    Article  Google Scholar 

  4. Fu H, Zhu W, Xu ZF, Chen P, Yan CZ, Zhou K, Shi YS (2019) Effect of silicon addition on the microstructure, mechanical and thermal properties of C-f/SiC composite prepared via selective laser sintering. J Alloys Compd 792:1045–1053

    Article  Google Scholar 

  5. Lin KJ, Hu KM, Gu DD (2019) Metallic integrated thermal protection structures inspired by the Norway spruce stem: design, numerical simulation and selective laser melting fabrication. Opt Laser Technol 115:9–19

    Article  Google Scholar 

  6. Yan WT, Ge WJ, Qian Y, Lin S, Zhou B, Liu WK, Lin F, Wagner GJ (2017) Multi-physics modeling of single/multiple-track defect mechanisms in electron beam selective melting. Acta Mater 134:324–333

    Article  Google Scholar 

  7. Donoghue J, Antonysamy AA, Martina F, Colegrove PA, Williams SW, Prangnell PB (2016) The effectiveness of combining rolling deformation with wire-arc additive manufacture on beta-grain refinement and texture modification in Ti-6Al-4V. Mater Charact 114:103–114

    Article  Google Scholar 

  8. Zhang Z, Tan ZJ, Li JY, Zu YF, Liu WW, Sha JJ (2019) Experimental and numerical studies of re-stirring and re-heating effects on mechanical properties in friction stir additive manufacturing. Int J Adv Manuf Technol 104:767–784. https://doi.org/10.1007/s00170-019-03917-6

    Article  Google Scholar 

  9. Li WY, Yang K, Yin S, Yang XW, Xu YX, Lupoi R (2018) Solid-state additive manufacturing and repairing by cold spraying: a review. J Mater Sci Technol 34:440–457

    Article  Google Scholar 

  10. Roberts IA, Wang CJ, Esterlein R, Stanford M, Mynors DJ (2009) A three-dimensional finite element analysis of the temperature field during laser melting of metal powders in additive layer manufacturing. Int J Mach Tools Manuf 49:916–923

    Article  Google Scholar 

  11. Du J, Wang X, Bai H, Zhao GX, Zhang YB (2017) Numerical analysis of fused-coating metal additive manufacturing. Int J Therm Sci 114:342–351

    Article  Google Scholar 

  12. Heigel JC, Michaleris P, Reutzel EW (2015) Thermo-mechanical model development and validation of directed energy deposition additive manufacturing of Ti–6Al–4V. Addit Manuf 5:9–19

    Google Scholar 

  13. Lu XF, Lin X, Chiumenti M, Cervera M, Hu YL, Ji XL, Ma L, Yang HO, Huang WD (2019) Residual stress and distortion of rectangular and S-shaped Ti-6Al-4V parts by directed energy deposition: Modelling and experimental calibration. Addit Manuf 26:166–179

    Google Scholar 

  14. Mukherjee T, Zuback JS, Zhang W, DebRoy T (2019) Residual stresses and distortion in additively manufactured compositionally graded and dissimilar joints. Comput Mater Sci 143:325–337

    Article  Google Scholar 

  15. Heigel JC, Phan TQ, Fox JC, Gnaupel-Herold TH (2018) Experimental investigation of residual stress and its impact on machining in hybrid additive/subtractive manufacturing. Proc Manuf 26:929–940

    Google Scholar 

  16. Biegler M, Marko A, Graf B, Rethmeier M (2018) Finite element analysis of in-situ distortion and bulging for an arbitrarily curved additive manufacturing directed energy deposition geometry. Addit Manuf 24:264–272

    Google Scholar 

  17. Zinovieva O, Zinoviev A, Ploshikhin V (2018) Three-dimensional modeling of the microstructure evolution during metal additive manufacturing. Comput Mater Sci 141:207–220

    Article  Google Scholar 

  18. Zhang Z, Tan ZJ, Yao XX, Hu CP, Ge P, Wan ZY, Li JY, Wu Q (2019) Numerical methods for microstructural evolutions in laser additive manufacturing. Comput Math Appl 78:2296–2307. https://doi.org/10.1016/j.camwa.2018.07.011

  19. Su JZ, Xiao MZ, Zhang ZJ, Ye ZP, Jin X, Yang YC (2017) Microstructural morphology and evolution of austenite stainless steel deposited using pulsed laser and wire. Int J Adv Manuf Technol 93:3357–3370

    Article  Google Scholar 

  20. Ren B, Zhang M, Chen CJ, Wang XN, Zou T, Hu ZR (2017) Effect of heat treatment on microstructure and mechanical properties of stellite 12 fabricated by laser additive manufacturing. J Mater Eng Perform 26:5404–5413

    Article  Google Scholar 

  21. Ge P, Zhang Z, Tan ZJ, Hu CP, Zhao GZ, Guo X (2019) An integrated modeling of process-structure-property relationship in laser additive manufacturing of duplex titanium alloy. Int J Therm Sci 140:329–343

    Article  Google Scholar 

  22. Yan WT, Lin S, Kafka OL, Yu C, Liu ZL, Lian YP, Wolff S, Cao J, Wagner GJ, Liu WK (2018) Modeling process-structure-property relationships for additive manufacturing. Front Mech Eng 13:482–492

    Article  Google Scholar 

  23. Zhang Z, Ge P, Zhao GZ (2017) Numerical studies of post weld heat treatment on residual stresses in welded impeller. Int J Press Vessel Pip 153:1–14

    Article  Google Scholar 

  24. Cao J, Gharghouri MA, Nash P (2016) Finite-element analysis and experimental validation of thermal residual stress and distortion in electron beam additive manufactured Ti-6Al-4V build plates. J Mater Process Technol 237:409–419

    Article  Google Scholar 

  25. Ali H, Ghadbeigi H, Mumtaz K (2018) Residual stress development in selective laser-melted Ti6Al4V: a parametric thermal modelling approach. Int J Adv Manuf Technol 97:2621–2633

    Article  Google Scholar 

  26. Vasinonta A, Beuth JL, Griffith M (2007) Process maps for predicting residual stress and melt pool size in the laser-based fabrication of thin-walled structures. J Manuf Sci Eng 129:101–109

    Article  Google Scholar 

  27. An K, Yuan L, Dial L, Spinnelli I, Stoica AD, Gao Y (2017) Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing. Mater Des 135:122–132

    Article  Google Scholar 

  28. Somashekara MA, Naveenkumar M, Kumar A, Viswanath C, Simhambhatla S (2017) Investigations into effect of weld-deposition pattern on residual stress evolution for metallic additive manufacturing. Int J Adv Manuf Technol 90:2009–2025

    Article  Google Scholar 

  29. Ghasri-Khouzani M, Peng H, Rogge R, Attardo R, Ostiguy P, Neidig J, Billo R, Hoelzle D, Shankar MR (2017) Experimental measurement of residual stress and distortion in additively manufactured stainless steel components with various dimensions. Mater Sci Eng A707:689–700

    Article  Google Scholar 

  30. Kalentics N, Boillat E, Peyre P, Gorny C, Kenel C, Leinenbach C, Jhabvala J, Logé RE (2017) 3D laser shock peening—a new method for the 3D control of residual stresses in selective laser melting. Mater Des 130:350–356

    Article  Google Scholar 

  31. Fergani O, Berto F, Welo T, Liang SY (2017) Analytical modelling of residual stress in additive manufacturing. Fatigue Fract Eng Mater Struct 40:971–978

    Article  Google Scholar 

  32. Kundakcıoğlu E, Lazoglu I, Poyraz Ö, Yasa E, Cizicioğlu N (2018) Thermal and molten pool model in selective laser melting process of Inconel 625. Int J Adv Manuf Technol 95:3977–3984

    Article  Google Scholar 

  33. Manvatkar VD, Gokhale AA, Reddy GJ, Venkataramana A, De A (2011) Estimation of melt pool dimensions, thermal cycle, and hardness distribution in the laser-engineered net shaping process of austenitic stainless steel. Metall Mater Trans A 42:4080–4087

    Article  Google Scholar 

  34. Zhang ZD, Huang YZ, Kasinathan AR, Shahabad SI, Ali U, Mahmoodkhani Y, Toyserkani E (2019) 3-Dimensional heat transfer modeling for laser powder-bed fusion additive manufacturing with volumetric heat sources based on varied thermal conductivity and absorptivity. Opt Laser Technol 109:297–312

    Article  Google Scholar 

  35. Biegler M, Graf B, Rethmeier M (2018) In-situ distortions in LMD additive manufacturing walls can be measured with digital image correlation and predicted using numerical simulations. Addit Manuf 20:101–110

    Google Scholar 

  36. Wu JL (2011) Elasticity. Higher Education Press, Beijing (in Chinese)

    Google Scholar 

  37. Li R, Xiong J, Lei YY (2019) Investigation on thermal stress evolution induced by wire and arc additive manufacturing for circular thin-walled parts. J Manuf Process 40:59–67

    Article  Google Scholar 

  38. Wang HG (1989) Outline of Thermoelasticity. Tsinghua University Press, Beijing (in Chinese)

    Google Scholar 

  39. Xiong J, Lei YY, Li R (2017) Finite element analysis and experimental validation of thermal behavior for thin-walled parts in GMAW-based additive manufacturing with various substrate preheating temperatures. Appl Therm Eng 126:43–52

    Article  Google Scholar 

  40. Ji SY (2018) Mechanics of materials. Science Press, Beijing (in Chinese)

    Google Scholar 

Download references

Conflict of interest

The authors declare that they have no conflict of interest.

Funding

This study is funded by the National Natural Science Foundation of China (No. 11572074) and Liaoning Provincial Natural Science Foundation (2019-KF-05-07).

Author information

Authors and Affiliations

  1. Department of Engineering Mechanics, Faculty of Vehicle Engineering and Mechanics, State Key Laboratory of Structural Analysis for Industrial Equipment, Dalian University of Technology, Dalian, 116024, China

    Z. Zhang, P. Ge & X. X. Yao

  2. School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    T. Li & W. W. Liu

Authors
  1. Z. Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. Ge
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. X. X. Yao
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. T. Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. W. W. Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Z. Zhang.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, Z., Ge, P., Yao, X.X. et al. Numerical studies of residual states and scaling effects in laser-directed energy deposition additive manufacturing. Int J Adv Manuf Technol 108, 1233–1247 (2020). https://doi.org/10.1007/s00170-020-05300-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05300-2

Keywords

Search

Navigation