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Inherent strain approach to estimate residual stress and deformation in the laser powder bed fusion process for metal additive manufacturing—a state-of-the-art review

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Abstract

In recent years, metal additive manufacturing (AM) and particularly the laser powder bed fusion (LPBF) process have substantially grown in popularity in industrial applications due to its unique ability to produce a wide variety of components with complex geometry. The LPBF process is now an integral part of digital manufacturing and the industry 4.0 concept. However, a considerable amount of residual stress and deformation induced by the fast and intense heating/cooling cycle as well as phase change in each layer are still some important technical barriers in the LPBF process, giving rise to increasing inaccuracy and structural failure in some cases. Developing an efficient physics-based simulation model capable of predicting the induced residual stresses is, thus, of paramount importance to build parts with minimal distortion in a wide range of applications, while avoiding expensive and time-consuming experimental procedures. The simulation model also is efficiently utilized to investigate the effect of process parameters, material, and geometry on the development and redesign of parts. In the last decade, multi-scale process modeling frameworks have been developed to predict the residual stress and deformation cost-effectively in the parts fabricated by LPBF. The purpose of this survey is to systematically provide an in-depth overview of the inherent strain modeling approach with a focus more on the methodology development, highlighting the positive outcomes and limitations of recent investigations, followed by presenting potential future work to optimize this technique.

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Funding

This work was conducted as part of a project supported by the National Research Candida’s METALTec Industrial Research Group, the National Research Candida’s National Program Office (NPO), and the Metal Transformation Research and Innovation Consortium (CRITM) as well with grant number AM-113-3.

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  1. Department of Mechanical, Industrial & Aerospace Engineering, Concordia University, Montreal, QC, H3G 2W1, Canada

    Hossein Mohammadtaheri

  2. National Research Council Canada (NRC), 75 Boulevard de Mortagne, Boucherville, QC, J4B 6Y4, Canada

    Marjan Molavi-Zarandi

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  1. Hossein Mohammadtaheri
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  2. Ramin Sedaghati
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All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Hossein Mohammadtaheri. The first draft of the manuscript was written by Hossein Mohammadtaheri, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Mohammadtaheri, H., Sedaghati, R. & Molavi-Zarandi, M. Inherent strain approach to estimate residual stress and deformation in the laser powder bed fusion process for metal additive manufacturing—a state-of-the-art review. Int J Adv Manuf Technol 122, 2187–2202 (2022). https://doi.org/10.1007/s00170-022-10052-2

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