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In situ measurements and simulation of residual stresses and deformations in additively manufactured thin plates

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Abstract

In this work, the residual stresses and deformations developed during and after laser powder bed fusion (L-PBF) manufacture of thin quasi-2D metallic plates were investigated. Such thin structures are particularly susceptible to effects of residual stress development. A finite element analysis of the L-PBF process was validated with in situ force measurements for the first time for a thin horizontal plate. The predicted forces developed reached a steady growth rate in the corners of the sample of 4.25 N per layer deposited, compared to 3.1 to 3.6 N per layer measured by in situ load cells. The evolution of deformation and residual stress in a different configuration, thin vertical plates, during and after removal of support structures, was also studied numerically and experimentally. Here, the finite element results showed good qualitative and quantitative (to within about 30% on average) agreement for residual deformations and final geometries of the thin vertical structures when compared with stereoscopic digital image correlation measurements. The results from the simulations showed that through-thickness stresses and shear stresses are negligible, while in-plane stresses grow in magnitude during the build process and the subsequent cooling period but are relaxed when the supporting structures are severed and the built plates removed from the base-plate, leaving tension in first built layers and compression in the last built layers. The models provide a tool for designing support structures and processes for release of the structures from their supports and substrates.

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Notes

  1. Powder-specific properties as a ratio to bulk solid properties used to account for heat transfer in the powder.

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Funding

The research was supported by grants from both the EPSRC (grant no. EP/T013141/1) in the UK and NSF CMMI (grant no. 20–27082) in the USA.

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Authors and Affiliations

  1. Department of Aerospace Engineering, University of Illinois, Urbana-Champaign, USA

    Pouria Khanbolouki & John Lambros

  2. Department of Mechanical & Aerospace Engineering, University of Liverpool, Liverpool, UK

    Rodrigo Magana-Carranza & Eann Patterson

  3. Meta Consulting LDA, Foz do Arelho, Portugal

    Chris Sutcliffe

Authors
  1. Pouria Khanbolouki
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  2. Rodrigo Magana-Carranza
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  3. Chris Sutcliffe
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  4. Eann Patterson
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  5. John Lambros
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Contributions

Methodology, formal analysis and visualization were performed by Pouria Khanbolouki. Experimental investigation and data curation were performed by Rodrigo Magana-Carranza. Conceptualization, supervision and funding acquisition were performed by Chris Sutcliffe, Eann Patterson and John Lambros. The first draft of the manuscript was written by Pouria Khanbolouki, and all authors commented on previous versions of the manuscript. Pouria Khanbolouki, Chris Sutcliffe, Eann Patterson and John Lambros read, edited and approved the final manuscript.

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Correspondence to John Lambros.

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Khanbolouki, P., Magana-Carranza, R., Sutcliffe, C. et al. In situ measurements and simulation of residual stresses and deformations in additively manufactured thin plates. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13577-w

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  • DOI: https://doi.org/10.1007/s00170-024-13577-w

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