Skip to main content

Advertisement

SpringerLink
Log in

Multiphysics modeling of in situ integration of directed energy deposition with ultrasonic nanocrystal surface modification

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

Abstract

In this paper, an in situ integration of the laser-assisted powder-based directed energy deposition (DED) process with a post-processing surface engineering technique called an ultrasonic nanocrystal surface modification (UNSM) is presented and analyzed with a multiphysics computational approach. The goal of this integrated process is to improve the quality of the DED built part by mitigating the high magnitude tensile residual stress in the built layer by incorporating compressive residual stress. The multiphysics, multi-scale computational modeling approach involves a meso-scale computational fluid dynamics (CFD) model interfaced with a macro-scale finite element method (FEM). The CFD model simulates powder feeding, transient thermal gradient, heat transfer, and laser-assisted powder-based DED melt pool dynamics. This model is then coupled with FEM to evaluate the effect of the UNSM process on the residual stress. The simulation results show that UNSM incorporates compressive residual stress to a depth of ~800 μm for a single built layer of ~1100 μm and shifts a region with an average of ~170 MPa tensile residual stress into one with an average of ~600 MPa compressive stress.

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

Similar content being viewed by others

Data availability

Since the data is part of an ongoing study, it cannot be shared to reproduce the results.

References

  1. Li W, Soshi M (2019) Modeling analysis of grain morphologies in directed energy deposition (DED) coating with different laser scanning patterns. Mater Lett 251:8–12. https://doi.org/10.1016/j.matlet.2019.05.027

    Article  Google Scholar 

  2. Gharbi M, Peyre P, Gorny C et al (2013) Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti-6Al-4V alloy. J Mater Process Technol 213:791–800. https://doi.org/10.1016/j.jmatprotec.2012.11.015

    Article  Google Scholar 

  3. Tabernero I, Lamikiz A, Martínez S et al (2012) Modelling of energy attenuation due to powder flow-laser beam interaction during laser cladding process. J Mater Process Technol 212:516–522. https://doi.org/10.1016/j.jmatprotec.2011.10.019

    Article  Google Scholar 

  4. Zhi’En ET, Pang JHL (2021) Kaminski J Directed energy deposition build process control effects on microstructure and tensile failure behaviour. J Mater Process Technol 294:117139. https://doi.org/10.1016/j.jmatprotec.2021.117139

    Article  Google Scholar 

  5. Mazumder J, Dutta D, Kikuchi N, Ghosh A (2000) Closed loop direct metal deposition: art to part. Opt Lasers Eng 34:397–414. https://doi.org/10.1016/S0143-8166(00)00072-5

    Article  Google Scholar 

  6. Chen Y, Clark SJ, Huang Y et al (2021) In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel. Mater Lett 286:129205. https://doi.org/10.1016/j.matlet.2020.129205

    Article  Google Scholar 

  7. Shiomil M, Osakadal K, Nakamural K et al (2004) Residual stress within metallic model made by selective laser melting process. CIRP 53:195–198. https://doi.org/10.1016/S0007-8506(07)60677-5

    Article  Google Scholar 

  8. Mercelis P, Kruth JP (2006) Residual stresses in selective laser sintering and selective laser melting. Rapid Prototyp J 12:254–265. https://doi.org/10.1108/13552540610707013

    Article  Google Scholar 

  9. Buchbinder D, Meiners W, Pirch N et al (2014) Investigation on reducing distortion by preheating during manufacture of aluminum components using selective laser melting. J Laser Appl 26:012004. https://doi.org/10.2351/1.4828755

    Article  Google Scholar 

  10. Lu X, Lin X, Chiumenti M et al (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. https://doi.org/10.1016/j.addma.2019.02.001

    Article  Google Scholar 

  11. Lu X, Chiumenti M, Cervera M et al (2021) Substrate design to minimize residual stresses in directed energy deposition AM processes. Mater Des 202:109525. https://doi.org/10.1016/j.matdes.2021.109525

    Article  Google Scholar 

  12. Sridharan N, Bunn J, Kottman M et al (2021) Consumable development to tailor residual stress in parts fabricated using directed energy deposition processes. Addit Manuf 39:101837. https://doi.org/10.1016/j.addma.2021.101837

    Article  Google Scholar 

  13. Jarred CH (2015) Thermo-mechanical model development and experimental validation for directed energy deposition additive manufacturing processes. Dissertation, The Pennsylvania State University

  14. Wang Z, Palmer TA, Beese AM (2016) Effect of processing parameters on microstructure and tensile properties of austenitic stainless steel 304L made by directed energy deposition additive manufacturing. Acta Mater 110:226–235. https://doi.org/10.1016/j.actamat.2016.03.019

    Article  Google Scholar 

  15. Berumen S, Bechmann F, Lindner S et al (2010) Quality control of laser- and powder bed-based Additive Manufacturing (AM) technologies. Phys Procedia 5:617–622

    Article  Google Scholar 

  16. Tapia G, Elwany A (2014) A review on process monitoring and control in metal-based additive manufacturing. J Manuf Sci E T ASME. https://doi.org/10.1115/1.4028540

    Article  Google Scholar 

  17. Alimardani M, Fallah V, Iravani-Tabrizipour M, Khajepour A (2012) Surface finish in laser solid freeform fabrication of an AISI 303L stainless steel thin wall. J Mater Process Technol 212:113–119. https://doi.org/10.1016/j.jmatprotec.2011.08.012

    Article  Google Scholar 

  18. Stender M, Beghini L, Sugar J et al (2018) A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling. Addit Manuf 21:556–566. https://doi.org/10.1016/j.addma.2018.04.012

    Article  Google Scholar 

  19. Liu FQ, Wei L, Shi SQ, Wei HL (2020) On the varieties of build features during multi-layer laser directed energy deposition. Addit Manuf 36:101491. https://doi.org/10.1016/j.addma.2020.101491

    Article  Google Scholar 

  20. Dong JX, Xie XS, Zhang SH (1993) Enhancements of thermal structure stability in a Ni-base superalloy. Scr Metall Mater 28:1477–1482

    Article  Google Scholar 

  21. Kreitcberg A, Brailovski V, Turenne S (2017) Effect of heat treatment and hot isostatic pressing on the microstructure and mechanical properties of Inconel 625 alloy processed by laser powder bed fusion. Mater Sci Eng A 689:1–10. https://doi.org/10.1016/j.msea.2017.02.038

    Article  Google Scholar 

  22. Luo KY, Jing X, Sheng J et al (2016) Characterization and analyses on micro-hardness, residual stress and microstructure in laser cladding coating of 316L stainless steel subjected to massive LSP treatment. J Alloy Compd 673:158–169. https://doi.org/10.1016/j.jallcom.2016.02.266

    Article  Google Scholar 

  23. Chi J, Cai Z, Zhang H et al (2021) Combining manufacturing of titanium alloy through direct energy deposition and laser shock peening processes. Mater Des. https://doi.org/10.1016/j.matdes.2021.109626

    Article  Google Scholar 

  24. Sealy MP, Madireddy G, Li C, Guo YB (2016) Finite element modeling of hybrid additive manufacturing by laser shock peening. Solid Freeform Fabrication: Proceedings of the 27th Annual International

  25. Kalentics N, Boillat E, Peyre P et al (2017) Tailoring residual stress profile of selective laser melted parts by laser shock peening. Addit Manuf 16:90–97. https://doi.org/10.1016/j.addma.2017.05.008

    Article  Google Scholar 

  26. Gong Y, Li P (2019) Analysis of tool wear performance and surface quality in post milling of additive manufactured 316L stainless steel. J Mech Sci Technol 33:2387–2395. https://doi.org/10.1007/s12206-019-0237-x

    Article  Google Scholar 

  27. Farayibi PK, Abioye TE, Murray JW et al (2015) Surface improvement of laser clad Ti-6Al-4V using plain waterjet and pulsed electron beam irradiation. J Mater Process Technol 218:1–11. https://doi.org/10.1016/j.jmatprotec.2014.11.035

    Article  Google Scholar 

  28. Venkatesan K, Ramanujam R, Kuppan P (2014) Analysis of cutting forces and temperature in laser assisted machining of inconel 718 using taguchi method. Procedia Eng 97:1637–1646

    Article  Google Scholar 

  29. Schopphoven T, Gasser A, Wissenbach K, Poprawe R (2016) Investigations on ultra-high-speed laser material deposition as alternative for hard chrome plating and thermal spraying. J Laser Appl 28:022501. https://doi.org/10.2351/1.4943910

    Article  Google Scholar 

  30. Kalentics N, de Seijas MOV, Griffiths S et al (2020) 3D laser shock peening – A new method for improving fatigue properties of selective laser melted parts. Addit Manuf. https://doi.org/10.1016/j.addma.2020.101112

    Article  Google Scholar 

  31. Kalentics N, Sohrabi N, Tabasi HG et al (2019) Healing cracks in selective laser melting by 3D laser shock peening. Addit Manuf. https://doi.org/10.1016/j.addma.2019.100881

    Article  Google Scholar 

  32. Kalentics N, Burn A, Cloots M, Logé RE (2019) 3D laser shock peening as a way to improve geometrical accuracy in selective laser melting. Int J Adv Manuf Technol 101:1247–1254. https://doi.org/10.1007/s00170-018-3033-3

    Article  Google Scholar 

  33. Kalentics N, Boillat E, Peyre P et al (2017) 3D Laser shock peening — a new method for the 3D control of residual stresses in selective laser melting. Mater Des 130:350–356. https://doi.org/10.1016/j.matdes.2017.05.083

    Article  Google Scholar 

  34. Kalentics N, Huang K, Varela O, de Seijas M et al (2019) Laser shock peening: a promising tool for tailoring metallic microstructures in selective laser melting. J Mater Process Technol 266:612–618. https://doi.org/10.1016/j.jmatprotec.2018.11.024

    Article  Google Scholar 

  35. Amanov A, Cho IS, Kim DE, Pyun YS (2012) Fretting wear and friction reduction of CP titanium and Ti-6Al-4V alloy by ultrasonic nanocrystalline surface modification. Surf Coat Technol 207:135–142. https://doi.org/10.1016/j.surfcoat.2012.06.046

    Article  Google Scholar 

  36. Khan MK, Fitzpatrick ME, Wang QY et al (2018) Effect of ultrasonic nanocrystal surface modification on residual stress and fatigue cracking in engineering alloys. Fatigue Fract Eng Mater Struct 41:844–855. https://doi.org/10.1111/ffe.12732

    Article  Google Scholar 

  37. Cao XJ, Pyoun YS, Murakami R (2010) Fatigue properties of a S45C steel subjected to ultrasonic nanocrystal surface modification. Appl Surf Sci 256:6297–6303. https://doi.org/10.1016/j.apsusc.2010.04.007

    Article  Google Scholar 

  38. Kheradmandfard M, Kashani-Bozorg SF, Kim CL et al (2017) Nanostructured β-type titanium alloy fabricated by ultrasonic nanocrystal surface modification. Ultrason Sonochem 39:698–706. https://doi.org/10.1016/j.ultsonch.2017.03.061

    Article  Google Scholar 

  39. Cherif A, Pyoun Y, Scholtes B (2010) Effects of ultrasonic nanocrystal surface modification (UNSM) on residual stress state and fatigue strength of AISI 304. J Mater Eng Perform 19:282–286. https://doi.org/10.1007/s11665-009-9445-3

    Article  Google Scholar 

  40. Khan MK, Liu YJ, Wang QY et al (2016) Effect of ultrasonic nanocrystal surface modification on the characteristics of AISI 310 stainless steel up to very high cycle fatigue. Fatigue Fract Eng Mater Struct 39:427–438. https://doi.org/10.1111/ffe.12367

    Article  Google Scholar 

  41. Gill A, Telang A, Mannava SR et al (2013) Comparison of mechanisms of advanced mechanical surface treatments in nickel-based superalloy. Mater Sci Eng, A 576:346–355. https://doi.org/10.1016/j.msea.2013.04.021

    Article  Google Scholar 

  42. Kim MS, Park SH, Pyun YS, Shim DS (2020) Optimization of ultrasonic nanocrystal surface modification for surface quality improvement of directed energy deposited stainless steel 316L. J Market Res 9:15102–15122. https://doi.org/10.1016/j.jmrt.2020.10.092

    Article  Google Scholar 

  43. Kim MS, Jo YK, Park SH, Shim DS (2019) Application of ultrasonic nanocrystal surface modification for improving surface profile of DEDed AISI 316L. J Mech Sci Technol 33:5659–5667. https://doi.org/10.1007/s12206-019-1108-1

    Article  Google Scholar 

  44. Kim MS, Oh WJ, Baek GY et al (2020) Ultrasonic nanocrystal surface modification of high-speed tool steel (AISI M4) layered via direct energy deposition. J Mater Process Technol 277:116420. https://doi.org/10.1016/j.jmatprotec.2019.116420

    Article  Google Scholar 

  45. Sidhu KS (2018) Residual stress enhancement of additively manufactured Inconel 718 by laser shock peening and ultrasonic nano-crystal surface modification. Thesis, The University of Cincinnati

  46. Cho IS, Lee CS, Choi CH et al (2017) Effect of the ultrasonic nanocrystalline surface modification (UNSM) on bulk and 3D-printed AISI H13 tool steels. Metals. https://doi.org/10.3390/met7110510

    Article  Google Scholar 

  47. Mills KC (2002) Recommended values of thermophysical properties for selected commercial alloys. Woodhead Publishing Ltd, Cambridge, England

    Book  Google Scholar 

  48. Flow Science.Inc FLOW-3D 2022 R1. https://www.flow3d.com/products/flow-3d/flow-3d-2022r1/. Accessed 7 Mar 2022

  49. Wen SY, Shin YC, Murthy JY, Sojka PE (2009) Modeling of coaxial powder flow for the laser direct deposition process. Int J Heat Mass Transf 52:5867–5877. https://doi.org/10.1016/j.ijheatmasstransfer.2009.07.018

    Article  MATH  Google Scholar 

  50. Lee Y (2015) Simulation of laser additive manufacturing and its applications. Dissertation, The Ohio State University

  51. Gürtler FJ, Karg M, Leitz KH (2013) Schmidt M Simulation of laser beam melting of steel powders using the three-dimensional volume of fluid method. Phys Procedia 41:881–886. https://doi.org/10.1016/j.phpro.2013.03.162

    Article  Google Scholar 

  52. Hirt CW, Nichols BD (1981) Volume of Fluid (VOF) Method for the dynamics of free boundaries. J Comput Phys 39:201–225. https://doi.org/10.1016/0021-9991(81)90145-5

    Article  MATH  Google Scholar 

  53. Saldi ZS (2011) Marangoni driven free surface flows in liquid weld pools. Delft University of Technology, Thesis

    Google Scholar 

  54. Zhang YM, Lim CWJ, Tang C, Li B (2021) Numerical investigation on heat transfer of melt pool and clad generation in directed energy deposition of stainless steel. Int J Therm Sci. https://doi.org/10.1016/j.ijthermalsci.2021.106954

    Article  Google Scholar 

  55. Zhu G, Li D, Zhang A et al (2012) The influence of laser and powder defocusing characteristics on the surface quality in laser direct metal deposition. Opt Laser Technol 44:349–356. https://doi.org/10.1016/j.optlastec.2011.07.013

    Article  Google Scholar 

  56. de Freitas R, Teixeira P, Bezerra de Araújo D, Bragança A, da Cunha L (2014) Study of the gaussian distribution heat source model applied to numerical thermal simulations of TIG welding processes. Science & Engineering Journal 23:115–122

    Google Scholar 

  57. Karkalos NE, Markopoulos AP (2018) Determination of Johnson-Cook material model parameters by an optimization approach using the fireworks algorithm. Procedia Manufacturing 22:107–113. https://doi.org/10.1016/j.promfg.2018.03.017

    Article  Google Scholar 

  58. Dassault Systèmes (2021) ABAQUS 2021. https://www.3ds.com/products-services/simulia/products/abaqus/. Accessed 7 Mar 2022

  59. Amanov A, Lee SW, Pyun YS (2017) Low friction and high strength of 316L stainless steel tubing for biomedical applications. Mater Sci Eng, C 71:176–185. https://doi.org/10.1016/j.msec.2016.10.005

    Article  Google Scholar 

  60. Miedzinski M (2017) Materials for additive manufacturing by direct energy deposition. Chalmers University of Technology, Thesis

    Google Scholar 

  61. Balit Y (2019) Mechanical properties of additively manufactured or repaired single-track thickness structures by Directed Energy Deposition. Dissertation, The Polytechnic Institute of Paris

  62. Jun TS, Korsunsky AM (2010) Evaluation of residual stresses and strains using the Eigenstrain Reconstruction Method. Int J Solids Struct 47:1678–1686. https://doi.org/10.1016/j.ijsolstr.2010.03.002

    Article  MATH  Google Scholar 

  63. Hu Y, Yao Z (2008) Numerical simulation and experimentation of overlapping laser shock processing with symmetry cell. Int J Mach Tools Manuf 48:152–162. https://doi.org/10.1016/j.ijmachtools.2007.08.021

    Article  Google Scholar 

Download references

Funding

Lu received financial support from NSF, DE-NA0003962 and DE-NA-0003525, under CMMI-1726435, and the Louis A. Beecherl Jr. endowed chair. Qian also received financial support from NSF under CMMI-1335204.

Author information

Authors and Affiliations

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

    Kishore Mysore Nagaraja, Wei Li, Dong Qian & Hongbing Lu

  2. Department of Material Science and Engineering, University of North Texas, Denton, TX, USA

    Vijay Vasudevan

  3. Department of Mechanical Engineering, Sun Moon University, Asan, Korea

    Youngsik Pyun

Authors
  1. Kishore Mysore Nagaraja
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wei Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dong Qian
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Vijay Vasudevan
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Youngsik Pyun
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Hongbing Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Wei Li or Dong Qian.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent to publication

Authors have agreed and provided consent for the published version of the manuscript.

Competing interests

The authors declare no competing interests.

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

Nagaraja, K.M., Li, W., Qian, D. et al. Multiphysics modeling of in situ integration of directed energy deposition with ultrasonic nanocrystal surface modification. Int J Adv Manuf Technol 120, 5299–5310 (2022). https://doi.org/10.1007/s00170-022-09082-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09082-7

Keywords

Search

Navigation