Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing
Cracking resulting from residual stress at the solid-tooth support interface frequently occurs in laser powder bed fusion (LPBF) metallic additive manufacturing, and thus it is critical to predict possible cracking and design the support to prevent it. This study employs a combination of computation...
| Main Authors: | , |
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| Format: | Article |
| Language: | English |
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Elsevier
2023-12-01
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| Series: | Journal of Science: Advanced Materials and Devices |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2468217923000849 |
| _version_ | 1797387838262607872 |
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| author | Hai T. Tran Albert C. To |
| author_facet | Hai T. Tran Albert C. To |
| author_sort | Hai T. Tran |
| collection | DOAJ |
| description | Cracking resulting from residual stress at the solid-tooth support interface frequently occurs in laser powder bed fusion (LPBF) metallic additive manufacturing, and thus it is critical to predict possible cracking and design the support to prevent it. This study employs a combination of computational methods and experiments to predict cracking at the interface and, for the first time, determine the relationship between the critical J-integral and the contact area of the solid-tooth support interface. In particular, the finite element method-based global-local approach is used to perform the modified inherent strain analysis with homogenized material for the entire part (global), which is followed by the fracture mechanics-based J-integral analysis at conjectured vulnerable locations (local). Both numerical and experimental validations are conducted, showing that the local-global approach is accurate and efficient in crack prediction at the interface between the solid and the tooth support in as-built LPBF printed metals. It is found that given the same basic tooth unit design in the support structure, the critical J-integral increases at an approximate linear slope of 2 with a local contact area percentage (∼20–40%) at the solid-support interface. These results will enable support designers the flexibility to design the support contact area to prevent solid-tooth support cracking while ensuring the ease of support removal. |
| first_indexed | 2024-03-08T22:31:53Z |
| format | Article |
| id | doaj.art-fa501f7b8a584d34b34e3d3fe7365950 |
| institution | Directory Open Access Journal |
| issn | 2468-2179 |
| language | English |
| last_indexed | 2024-03-08T22:31:53Z |
| publishDate | 2023-12-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Science: Advanced Materials and Devices |
| spelling | doaj.art-fa501f7b8a584d34b34e3d3fe73659502023-12-18T04:24:37ZengElsevierJournal of Science: Advanced Materials and Devices2468-21792023-12-0184100615Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturingHai T. Tran0Albert C. To1Mechanical Engineering Department, Embry-Riddle Aeronautical University, Daytona Beach, FL 32114, USA; J. Mike Walker ‘66 Department of Mechanical Engineering, Texas A&M University, College Station, TX 77843, USA; Corresponding author. Mechanical Engineering Department, Embry-Riddle Aeronautical University, Daytona Beach, FL 32114, USA.Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA 15261, USACracking resulting from residual stress at the solid-tooth support interface frequently occurs in laser powder bed fusion (LPBF) metallic additive manufacturing, and thus it is critical to predict possible cracking and design the support to prevent it. This study employs a combination of computational methods and experiments to predict cracking at the interface and, for the first time, determine the relationship between the critical J-integral and the contact area of the solid-tooth support interface. In particular, the finite element method-based global-local approach is used to perform the modified inherent strain analysis with homogenized material for the entire part (global), which is followed by the fracture mechanics-based J-integral analysis at conjectured vulnerable locations (local). Both numerical and experimental validations are conducted, showing that the local-global approach is accurate and efficient in crack prediction at the interface between the solid and the tooth support in as-built LPBF printed metals. It is found that given the same basic tooth unit design in the support structure, the critical J-integral increases at an approximate linear slope of 2 with a local contact area percentage (∼20–40%) at the solid-support interface. These results will enable support designers the flexibility to design the support contact area to prevent solid-tooth support cracking while ensuring the ease of support removal.http://www.sciencedirect.com/science/article/pii/S2468217923000849Laser powder bed fusionTooth supportAdditive manufacturingFinite element simulationInherent strain methodJ-integral |
| spellingShingle | Hai T. Tran Albert C. To Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing Journal of Science: Advanced Materials and Devices Laser powder bed fusion Tooth support Additive manufacturing Finite element simulation Inherent strain method J-integral |
| title | Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing |
| title_full | Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing |
| title_fullStr | Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing |
| title_full_unstemmed | Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing |
| title_short | Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing |
| title_sort | cracking prediction at solid tooth support interface during laser powder bed fusion additive manufacturing |
| topic | Laser powder bed fusion Tooth support Additive manufacturing Finite element simulation Inherent strain method J-integral |
| url | http://www.sciencedirect.com/science/article/pii/S2468217923000849 |
| work_keys_str_mv | AT haittran crackingpredictionatsolidtoothsupportinterfaceduringlaserpowderbedfusionadditivemanufacturing AT albertcto crackingpredictionatsolidtoothsupportinterfaceduringlaserpowderbedfusionadditivemanufacturing |