Residual Stresses Control in Additive Manufacturing
Residual stresses are one of the primary causes for the failure of parts or systems in metal additive manufacturing (AM), since they easily induce crack propagation and structural distortion. Although the formation of residual stresses has been extensively studied, the core factors steering their de...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-12-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/5/4/138 |
| _version_ | 1797503335189708800 |
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| author | Xufei Lu Miguel Cervera Michele Chiumenti Xin Lin |
| author_facet | Xufei Lu Miguel Cervera Michele Chiumenti Xin Lin |
| author_sort | Xufei Lu |
| collection | DOAJ |
| description | Residual stresses are one of the primary causes for the failure of parts or systems in metal additive manufacturing (AM), since they easily induce crack propagation and structural distortion. Although the formation of residual stresses has been extensively studied, the core factors steering their development in AM have not been completely uncovered. To date, several strategies based on reducing the thermal gradients have been developed to mitigate the manifestation of residual stresses in AM; however, how to choose the optimal processing plan is still unclear for AM designers. In this regard, the concept of the yield temperature, related to the thermal deformation and the mechanical constraint, plays a crucial role for controlling the residual stresses, but it has not been duly investigated, and the corresponding approach to control stresses is also yet lacking. To undertake such study, a three-bar model is firstly used to illustrate the formation mechanism of the residual stress and its key causes. Next, an experimentally calibrated thermomechanical finite element model is used to analyze the sensitivity of the residual stresses to the scan pattern, preheating, energy density, and the part geometry and size, as well as the substrate constraints. Based on the numerical results obtained from this analysis, recommendations on how to minimize the residual stresses during the AM process are provided. |
| first_indexed | 2024-03-10T03:49:08Z |
| format | Article |
| id | doaj.art-cfe2ccf950c345e58c0383ccb3440638 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-10T03:49:08Z |
| publishDate | 2021-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-cfe2ccf950c345e58c0383ccb34406382023-11-23T09:01:51ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942021-12-015413810.3390/jmmp5040138Residual Stresses Control in Additive ManufacturingXufei Lu0Miguel Cervera1Michele Chiumenti2Xin Lin3International Centre for Numerical Methods in Engineering, Universidad Politécnica de Cataluña, 08034 Barcelona, SpainInternational Centre for Numerical Methods in Engineering, Universidad Politécnica de Cataluña, 08034 Barcelona, SpainInternational Centre for Numerical Methods in Engineering, Universidad Politécnica de Cataluña, 08034 Barcelona, SpainState Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an 710072, ChinaResidual stresses are one of the primary causes for the failure of parts or systems in metal additive manufacturing (AM), since they easily induce crack propagation and structural distortion. Although the formation of residual stresses has been extensively studied, the core factors steering their development in AM have not been completely uncovered. To date, several strategies based on reducing the thermal gradients have been developed to mitigate the manifestation of residual stresses in AM; however, how to choose the optimal processing plan is still unclear for AM designers. In this regard, the concept of the yield temperature, related to the thermal deformation and the mechanical constraint, plays a crucial role for controlling the residual stresses, but it has not been duly investigated, and the corresponding approach to control stresses is also yet lacking. To undertake such study, a three-bar model is firstly used to illustrate the formation mechanism of the residual stress and its key causes. Next, an experimentally calibrated thermomechanical finite element model is used to analyze the sensitivity of the residual stresses to the scan pattern, preheating, energy density, and the part geometry and size, as well as the substrate constraints. Based on the numerical results obtained from this analysis, recommendations on how to minimize the residual stresses during the AM process are provided.https://www.mdpi.com/2504-4494/5/4/138additive manufacturingresidual stress controlthermomechanical simulationstrategical assessment |
| spellingShingle | Xufei Lu Miguel Cervera Michele Chiumenti Xin Lin Residual Stresses Control in Additive Manufacturing Journal of Manufacturing and Materials Processing additive manufacturing residual stress control thermomechanical simulation strategical assessment |
| title | Residual Stresses Control in Additive Manufacturing |
| title_full | Residual Stresses Control in Additive Manufacturing |
| title_fullStr | Residual Stresses Control in Additive Manufacturing |
| title_full_unstemmed | Residual Stresses Control in Additive Manufacturing |
| title_short | Residual Stresses Control in Additive Manufacturing |
| title_sort | residual stresses control in additive manufacturing |
| topic | additive manufacturing residual stress control thermomechanical simulation strategical assessment |
| url | https://www.mdpi.com/2504-4494/5/4/138 |
| work_keys_str_mv | AT xufeilu residualstressescontrolinadditivemanufacturing AT miguelcervera residualstressescontrolinadditivemanufacturing AT michelechiumenti residualstressescontrolinadditivemanufacturing AT xinlin residualstressescontrolinadditivemanufacturing |