Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturing
Controlling distortion in laser powder-bed fusion additive manufacturing is of critical importance especially for thin-wall structures, which typically experience significant deformation and buckling during the build process. We examine this issue from the perspective of design by systematically per...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2022-03-01
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| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127522001101 |
| _version_ | 1819159469401047040 |
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| author | G. Vastola W.J. Sin C.-N. Sun N. Sridhar |
| author_facet | G. Vastola W.J. Sin C.-N. Sun N. Sridhar |
| author_sort | G. Vastola |
| collection | DOAJ |
| description | Controlling distortion in laser powder-bed fusion additive manufacturing is of critical importance especially for thin-wall structures, which typically experience significant deformation and buckling during the build process. We examine this issue from the perspective of design by systematically performing numerical simulations of the additive process of tubular components as a function of part design, including fillet radius, wall thickness, tube width and height. It is found that round corners, as opposed to sharp corners, suppress distortion even at small wall thickness (400 µm), while part width has a greater impact on distortion than part height. The buckling behavior of such structures is numerically investigated and analysis results show that for designs most prone to distortion, a critical height exists below which the component is distortion-free. The modeling was experimentally validated by manufacturing thin-wall components of IN718 alloy using the EOS M290 printer. The findings provide practical guidelines to manufacture metallic thin-wall tubular components with minimal to no distortion using powder-bed fusion additive manufacturing. |
| first_indexed | 2024-12-22T16:41:03Z |
| format | Article |
| id | doaj.art-12422ddaf4714316953ffedddb3d7079 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-12-22T16:41:03Z |
| publishDate | 2022-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-12422ddaf4714316953ffedddb3d70792022-12-21T18:19:52ZengElsevierMaterials & Design0264-12752022-03-01215110489Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturingG. Vastola0W.J. Sin1C.-N. Sun2N. Sridhar3A*STAR Institute of High Performance Computing, 1 Fusionopolis Way, #16-16 Connexis, Singapore 138632, Singapore; Corresponding author.A*STAR Singapore Institute of Manufacturing Technology, 2 Fusionopolis Way, Singapore 138634, SingaporeA*STAR Singapore Institute of Manufacturing Technology, 2 Fusionopolis Way, Singapore 138634, SingaporeA*STAR Institute of High Performance Computing, 1 Fusionopolis Way, #16-16 Connexis, Singapore 138632, SingaporeControlling distortion in laser powder-bed fusion additive manufacturing is of critical importance especially for thin-wall structures, which typically experience significant deformation and buckling during the build process. We examine this issue from the perspective of design by systematically performing numerical simulations of the additive process of tubular components as a function of part design, including fillet radius, wall thickness, tube width and height. It is found that round corners, as opposed to sharp corners, suppress distortion even at small wall thickness (400 µm), while part width has a greater impact on distortion than part height. The buckling behavior of such structures is numerically investigated and analysis results show that for designs most prone to distortion, a critical height exists below which the component is distortion-free. The modeling was experimentally validated by manufacturing thin-wall components of IN718 alloy using the EOS M290 printer. The findings provide practical guidelines to manufacture metallic thin-wall tubular components with minimal to no distortion using powder-bed fusion additive manufacturing.http://www.sciencedirect.com/science/article/pii/S0264127522001101Design for additive manufacturingDistortionModeling and simulationDesign map |
| spellingShingle | G. Vastola W.J. Sin C.-N. Sun N. Sridhar Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturing Materials & Design Design for additive manufacturing Distortion Modeling and simulation Design map |
| title | Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturing |
| title_full | Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturing |
| title_fullStr | Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturing |
| title_full_unstemmed | Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturing |
| title_short | Design guidelines for suppressing distortion and buckling in metallic thin-wall structures built by powder-bed fusion additive manufacturing |
| title_sort | design guidelines for suppressing distortion and buckling in metallic thin wall structures built by powder bed fusion additive manufacturing |
| topic | Design for additive manufacturing Distortion Modeling and simulation Design map |
| url | http://www.sciencedirect.com/science/article/pii/S0264127522001101 |
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