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Finite Element Prediction of Residual Stress in Rhombic Dodecahedron Ti-6Al-4V Titanium Alloy Additively Manufactured by Electron Beam Melting

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Acta Metallurgica Sinica (English Letters) Aims and scope

Abstract

In this work, a three-dimensional nonlinear transient thermo-mechanically coupled finite element model (FEM) is established to investigate the variation in temperature and stress fields during electron beam melting (EBM) of rhombic dodecahedron Ti-6Al-4V alloy. The influence of the processing parameters on the temperature and residual stress evolutions was predicted and verified against existing literature data. The calculated results indicate that the interlayer cooling time has very little effect on both the temperature and stress evolutions, indicating that the interlayer cooling time can be set up as short as possible to reduce manufacturing time. It is presented that the residual stress of the intersection is higher than that of non-intersection. With increasing preheating temperature, the residual stress decreases continuously, which is about 20%–30% for every 50 °C rise in temperature. The temperature and stress fields repeated every four layers with the complex periodic scanning strategy. Both x and y-component residual stresses are tensile stresses, while z-component stress is weak compressive or tensile stress in typical paths. It is proposed that the interlayer cooling is necessary to obtain a rhombic dodecahedron with low residual stress. These results can bring insights into the understanding of the residual stress during EBM.

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Acknowledgements

This work was financially supported by the Natural Science Foundation of Shandong Province, China (No. ZR2019MEM012).

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Authors and Affiliations

  1. Institute for Advanced Studies in Precision Materials, Yantai University, Yantai, 264005, China

    Shangzhou Zhang, Yuankang Wang, Fanchao Meng & Hua Zhang

  2. School of Electromechanical and Automotive Engineering, Yantai University, Yantai, 264005, China

    Bing Zhou & Li Zhou

  3. Institute of Metal Research, Chinese Academy of Sciences, Shenyang, 110016, China

    Shujun Li & Qingmiao Hu

Authors
  1. Shangzhou Zhang
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  2. Yuankang Wang
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  3. Bing Zhou
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Correspondence to Shangzhou Zhang or Li Zhou.

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Zhang, S., Wang, Y., Zhou, B. et al. Finite Element Prediction of Residual Stress in Rhombic Dodecahedron Ti-6Al-4V Titanium Alloy Additively Manufactured by Electron Beam Melting. Acta Metall. Sin. (Engl. Lett.) 36, 35–47 (2023). https://doi.org/10.1007/s40195-022-01446-y

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  • DOI: https://doi.org/10.1007/s40195-022-01446-y

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