Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method
In metal 3D printing with Selective Laser Melting (SLM) technology, due to large thermal gradients, the residual stress (RS) distribution is complicated to predict and control. RS can distort the shape of the components, causing severe failures in fabrication or functionality. Thus, several research...
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2022-09-01
|
| Series: | Materials |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1944/15/17/6057 |
| _version_ | 1797494475347460096 |
|---|---|
| author | Quoc-Phu Ma Jakub Mesicek Frantisek Fojtik Jiri Hajnys Pavel Krpec Marek Pagac Jana Petru |
| author_facet | Quoc-Phu Ma Jakub Mesicek Frantisek Fojtik Jiri Hajnys Pavel Krpec Marek Pagac Jana Petru |
| author_sort | Quoc-Phu Ma |
| collection | DOAJ |
| description | In metal 3D printing with Selective Laser Melting (SLM) technology, due to large thermal gradients, the residual stress (RS) distribution is complicated to predict and control. RS can distort the shape of the components, causing severe failures in fabrication or functionality. Thus, several research papers have attempted to quantify the RS by designing geometries that distort in a predictable manner, including the Bridge Curvature Method (BCM). Being different from the existing literature, this paper provides a new perspective of the RS build-up in aluminum parts produced with SLM using a combination of experiments and simulations. In particular, the bridge samples are printed with AlSi10Mg, of which the printing process and the RS distribution are experimentally assessed with the Hole Drilling Method (HDM) and simulated using ANSYS and Simufact Additive. Subsequently, on the basis of the findings, suggestions for improvements to the BCM are made. Throughout the assessment of BCM, readers can gain insights on how RS is built-up in metallic 3D-printed components, some available tools, and their suitability for RS prediction. These are essential for practitioners to improve the precision and functionality of SLM parts should any post-subtractive or additive manufacturing processes be employed. |
| first_indexed | 2024-03-10T01:34:50Z |
| format | Article |
| id | doaj.art-baf05bd31ffb42dfa8fa5ebe529c127d |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T01:34:50Z |
| publishDate | 2022-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-baf05bd31ffb42dfa8fa5ebe529c127d2023-11-23T13:34:49ZengMDPI AGMaterials1996-19442022-09-011517605710.3390/ma15176057Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature MethodQuoc-Phu Ma0Jakub Mesicek1Frantisek Fojtik2Jiri Hajnys3Pavel Krpec4Marek Pagac5Jana Petru6Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70833 Ostrava, Czech RepublicDepartment of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70833 Ostrava, Czech RepublicDepartment of Applied Mechanics, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70833 Ostrava, Czech RepublicDepartment of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70833 Ostrava, Czech RepublicV-NASS, A.S., Halasova 2938/1a, 70300 Ostrava, Czech RepublicDepartment of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70833 Ostrava, Czech RepublicDepartment of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70833 Ostrava, Czech RepublicIn metal 3D printing with Selective Laser Melting (SLM) technology, due to large thermal gradients, the residual stress (RS) distribution is complicated to predict and control. RS can distort the shape of the components, causing severe failures in fabrication or functionality. Thus, several research papers have attempted to quantify the RS by designing geometries that distort in a predictable manner, including the Bridge Curvature Method (BCM). Being different from the existing literature, this paper provides a new perspective of the RS build-up in aluminum parts produced with SLM using a combination of experiments and simulations. In particular, the bridge samples are printed with AlSi10Mg, of which the printing process and the RS distribution are experimentally assessed with the Hole Drilling Method (HDM) and simulated using ANSYS and Simufact Additive. Subsequently, on the basis of the findings, suggestions for improvements to the BCM are made. Throughout the assessment of BCM, readers can gain insights on how RS is built-up in metallic 3D-printed components, some available tools, and their suitability for RS prediction. These are essential for practitioners to improve the precision and functionality of SLM parts should any post-subtractive or additive manufacturing processes be employed.https://www.mdpi.com/1996-1944/15/17/6057selective laser melting (SLM)residual stresshole drilling method (HDM)bridge curvature method (BCM)finite element analysis (FEA)aluminum alloys |
| spellingShingle | Quoc-Phu Ma Jakub Mesicek Frantisek Fojtik Jiri Hajnys Pavel Krpec Marek Pagac Jana Petru Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method Materials selective laser melting (SLM) residual stress hole drilling method (HDM) bridge curvature method (BCM) finite element analysis (FEA) aluminum alloys |
| title | Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method |
| title_full | Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method |
| title_fullStr | Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method |
| title_full_unstemmed | Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method |
| title_short | Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method |
| title_sort | residual stress build up in aluminum parts fabricated with slm technology using the bridge curvature method |
| topic | selective laser melting (SLM) residual stress hole drilling method (HDM) bridge curvature method (BCM) finite element analysis (FEA) aluminum alloys |
| url | https://www.mdpi.com/1996-1944/15/17/6057 |
| work_keys_str_mv | AT quocphuma residualstressbuildupinaluminumpartsfabricatedwithslmtechnologyusingthebridgecurvaturemethod AT jakubmesicek residualstressbuildupinaluminumpartsfabricatedwithslmtechnologyusingthebridgecurvaturemethod AT frantisekfojtik residualstressbuildupinaluminumpartsfabricatedwithslmtechnologyusingthebridgecurvaturemethod AT jirihajnys residualstressbuildupinaluminumpartsfabricatedwithslmtechnologyusingthebridgecurvaturemethod AT pavelkrpec residualstressbuildupinaluminumpartsfabricatedwithslmtechnologyusingthebridgecurvaturemethod AT marekpagac residualstressbuildupinaluminumpartsfabricatedwithslmtechnologyusingthebridgecurvaturemethod AT janapetru residualstressbuildupinaluminumpartsfabricatedwithslmtechnologyusingthebridgecurvaturemethod |