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A predictive model for in situ distortion correction in laser powder bed fusion using laser shock peen forming

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Abstract

Described is a hybrid metal additive manufacturing (AM) method that integrates in situ laser shock peen (LSP) forming with laser powder bed fusion (PBF) to mitigate vertical distortions during part builds. LSP has recently been proposed to reduce tensile residual stresses during selective laser melting (SLM). The effects of LSP on part distortion, however, have not been rigorously examined. It is proposed here that SLM can be integrated with in situ LSP forming to reduce distortion of the upper surface of parts during or after printing. To study the distortion correction capability, a 2-stage computational framework is created, which includes physics-based models of the SLM process and LSP treatment. Stage 1 includes thermomechanical SLM simulation to predict surface geometry and is applied to model four 50-μm layers of a 316L part having a 4 mm × 4 mm footprint. Stage 2 of the framework includes an elastic-plastic thermomechanical shock-wave simulation to predict LSP surface treatment forming effects. Surface distortion is examined for varying laser spot size, overlap, and part temperatures from 300 to 500 K, using a nanosecond-pulsed infrared laser. For the 316L SLM sample, the upper surface is predicted to have \(\sim \) 9-μm vertical distortion on the 200-μm 4-layer build. With a 2-μm allowable distortion, only 44.13% of the surface initially conforms. After one LSP forming treatment at 300 K, conformance improves to 84.75%. After a third LSP forming, with 50% laser power-density increase, surface conformance increases to 91%, demonstrating potential of the hybrid AM-LSP process in reducing finish-machining.

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Funding

This work was supported in part by the US National Science Foundation CMMI-1762722.

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Authors and Affiliations

  1. Department of Mechanical Engineering, The University of Texas at Dallas, Richardson, TX, 75080, USA

    Sumair Sunny, Haoliang Yu, Ritin Mathews & Arif Malik

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  1. Sumair Sunny
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  4. Arif Malik
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Correspondence to Arif Malik.

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Author contributions

All authors contributed to the study conception and design. Model development and analysis were performed by Sumair Sunny, Haoliang Yu, and Ritin Mathews. The first draft of the manuscript was written by Sumair Sunny and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript. Dr. Arif Malik supervised the project and acquired the funding. Dr. Arif Malik also reviewed and edited the presented work.

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Sunny, S., Yu, H., Mathews, R. et al. A predictive model for in situ distortion correction in laser powder bed fusion using laser shock peen forming. Int J Adv Manuf Technol 112, 1319–1337 (2021). https://doi.org/10.1007/s00170-020-06399-z

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  • DOI: https://doi.org/10.1007/s00170-020-06399-z

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