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Study on the Effect of Scanning Strategy on Residual Stress in Laser Additive Manufacturing with the Laser Ultrasound Technique

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Abstract

Background

During the laser additive manufacturing (LAM) process large temperature gradients can form, generating a mismatch in deformation that can lead to high level of residual stress. The stress can have irreversible effects such as warping and cracking of parts during and post manufacturing.

Objective

One of the most important LAM parameters that should be controlled carefully in order to effectively manage residual stress is the scanning strategy. This study presents an evaluation of six different scanning strategies, namely reciprocating, 90° reciprocating, line, screwing, reciprocating overlapping and island scanning strategies with respect to their effect on residual stress.

Methods

Laser ultrasound technology, as an advanced nondestructive testing method, is applied to measure the residual stress distribution under different scanning strategies for the first time. The surface wave generated by laser is used to evaluate the plane stress state within the surface layer of the specimen.

Results

The results show that the island scanning strategy is found to contribute to the least average residual stress, and lowered residual stress by up to 45% relative to the line scanning strategy. The overall stress level is island < reciprocation overlapping < screwing < 90° reciprocating < reciprocating < line. Further to this, the effect of inspection path on the results of residual stress measurement is discussed and the concept of optimal inspection path is proposed for the first time.

Conclusions

Laser ultrasound method can effectively measure the residual stress in laser additive manufacturing, and the research can serve as useful guidelines for engineers and designers to restrain and evaluate residual stress in LAM.

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Acknowledgements

This study is supported by the National Natural Science Foundation of China Project (Grant No. 51771051), the Natural Science Foundation of Liaoning Province Project (Grant No. 2021-MS-102) and the Fundamental Research Funds for the Central Universities (Grant No. N2105021). Meanwhile, the authors would like to thank senior engineer Su and Li of AVIC 601 Institute for helping us to complete the laser additive manufacturing experiment.

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Authors and Affiliations

  1. College of Sciences, Northeastern University, Shenyang, 110819, China

    Y. Zhan, H. Xu & W. Du

  2. Key Laboratory for Anisotropy and Texture of Materials Ministry of Education, Northeastern University, Shenyang, 110819, China

    C. Liu

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  1. Y. Zhan
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  2. H. Xu
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  3. W. Du
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  4. C. Liu
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Correspondence to Y. Zhan.

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The authors do not have any conflicts of interest to disclose and this work did not involve human or animal participants.

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Zhan, Y., Xu, H., Du, W. et al. Study on the Effect of Scanning Strategy on Residual Stress in Laser Additive Manufacturing with the Laser Ultrasound Technique. Exp Mech 62, 563–572 (2022). https://doi.org/10.1007/s11340-021-00795-6

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  • DOI: https://doi.org/10.1007/s11340-021-00795-6

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