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Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS

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Abstract

Additive manufacturing enables the production of previously unachievable designs in conjunction with time and cost savings. However, spatially and temporally fluctuating thermal histories can lead to residual stress states and microstructural variations that challenge conventional assumptions used to predict part performance. Numerical simulations offer a viable way to explore the root causes of these characteristics, and can provide insight into methods of controlling them. Here, the thermal history of a 304L stainless steel cylinder produced using the Laser Engineered Net Shape process is simulated using finite element analysis (FEA). The resultant thermal history is coupled to both a solid mechanics FEA simulation to predict residual stress and a kinetic Monte Carlo model to predict the three-dimensional grain structure evolution. Experimental EBSD measurements of grain structure and in-process infrared thermal data are compared to the predictions.

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Acknowledgements

The authors would like to acknowledge Dave Keicher for support and development of the LENS process, Sam Subia, Tim Shelton, and the Sierra team for computational development and support, and Joe Michael, Alice Kilgo, Sara Dickens, Jay Carroll, and Philip Noell for EBSD work and fruitful discussions. Thoughtful reviews from Fadi Abdeljawad and Brad Trembacki are also greatly appreciated. Finally, the authors would like to acknowledge funding provided by the Born Qualified LDRD and thank Allen Roach (PI). Sandia National Laboratories is a multimission laboratory managed and operated by National Technology and Engineering Solutions of Sandia, LLC., a wholly owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

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Authors and Affiliations

  1. Sandia National Laboratories, PO Box 5800, MS 0346, Albuquerque, NM, 87185, USA

    Kyle L. Johnson

  2. Sandia National Laboratories, PO Box 5800, Albuquerque, NM, 87185, USA

    Theron M. Rodgers, Olivia D. Underwood, Jonathan D. Madison, Kurtis R. Ford, Shaun R. Whetten, Daryl J. Dagel & Joseph E. Bishop

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  1. Kyle L. Johnson
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Correspondence to Kyle L. Johnson.

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Johnson, K.L., Rodgers, T.M., Underwood, O.D. et al. Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS. Comput Mech 61, 559–574 (2018). https://doi.org/10.1007/s00466-017-1516-y

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