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Influence of process parameters on temperature and residual stress distributions of the deposited part by a Ti-6Al-4V wire feeding type direct energy deposition process

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Abstract

Distributions of temperature and residual stress of the deposition bead and the substrate during a wire feeding type direct energy deposition (DED) process are crucial to avoid undesired thermal effects and premature failure of the fabricated part due to repeated heating and cooling cycles during successive deposition. The goal of the paper is to investigate the influence of process parameters on distributions of temperature and residual stress of the deposited bead and the substrate for a single layer deposition through thermo-mechanical finite element analyses (FEAs). Ti-6Al-4V is chosen as the material of the wire. The effects of the power of the laser, the travel speed of the table and the length of the bead on the formation of the heat affected zone (HAZ) and the stress influenced region (SIR) are quantitatively examined using the results of FEAs. From the results of the examination, an appropriate gap between adjacent beads for successive deposition is proposed to reduce undesirable thermal effects and residual stress of the part fabricated by the Ti-6Al-4V wire feeding type DED process.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Chosun University, Gwangju, 61452, Korea

    Bih Lii Chua, Ho Jin Lee & Dong-Gyu Ahn

  2. Department of Nano-Convergence Mechanical Systems, Korea Institute of Machinery and Materials, Daejeon, 34103, Korea

    Jae Gu Kim

Authors
  1. Bih Lii Chua
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  2. Ho Jin Lee
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  3. Dong-Gyu Ahn
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  4. Jae Gu Kim
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Corresponding author

Correspondence to Dong-Gyu Ahn.

Additional information

Recommended by Editor Hyung Wook Park

Bih Lii Chua received his B.S. and M.S. degrees from University Malaysia Sabah, Malaysia in 2004 and 2008, respectively. He is currently pursuing his Ph.D. in Chosun University, Korea. His research interests are modeling and simulation of metal additive manufacturing processes using laser and electron beam.

Ho-Jin Lee received his B.S. degree from Chosun University, Korea in 2012. He then received M.S. degree from Chosun University, Korea in 2014. Mr. Lee’s research interests include metal & plastic forming processes, molds & die and development & application of 3D printing technology.

Dong-Gyu Ahn received his B.S. degree from the Busan National University, Korea in 1992. He then received his M.S. and Ph.D. degrees from KAIST, Korea in 1994 and 2002, respectively. Dr. Ahn is currently a Professor at the Department of Mechanical Engineering, Chosun University, Korea. Dr. Ahn’s research interests include development and application of 3D printing technology, rapid manufacturing, lightweight sandwich plate, and mold and die.

Jae-Gu Kim received his B.S. and M.S. degrees from Chounbuk National University, Korea in 1992 and 1994, respectively. He then received his Ph.D. degree from KAIST, Korea in 2007. Dr. Kim is currently a Principal Reseracher at the Korea Institute of Machinery and Materials, Korea. Dr. Kim’s research interests include laser micro machining and laser-wire additive manufacturing processes.

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Chua, B.L., Lee, H.J., Ahn, DG. et al. Influence of process parameters on temperature and residual stress distributions of the deposited part by a Ti-6Al-4V wire feeding type direct energy deposition process. J Mech Sci Technol 32, 5363–5372 (2018). https://doi.org/10.1007/s12206-018-1035-6

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  • DOI: https://doi.org/10.1007/s12206-018-1035-6

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