The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along...
| Main Authors: | , , , , |
|---|---|
| Other Authors: | |
| Format: | Journal Article |
| Language: | English |
| Published: |
2024
|
| Subjects: | |
| Online Access: | https://hdl.handle.net/10356/180594 |
| _version_ | 1826123437277446144 |
|---|---|
| author | Yan, Zhiqiang Wu, Kaiwen Xiao, Zhongmin Hui, Jizhuang Lv, Jingxiang |
| author2 | School of Mechanical and Aerospace Engineering |
| author_facet | School of Mechanical and Aerospace Engineering Yan, Zhiqiang Wu, Kaiwen Xiao, Zhongmin Hui, Jizhuang Lv, Jingxiang |
| author_sort | Yan, Zhiqiang |
| collection | NTU |
| description | The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along which the laser head scans powders within given area, is crucial, but clearly defined criteria for scanning strategy design are lacking. In this study, a three-dimensional finite element model (FEM) of the SLM process for manufacturing a WE43 alloy component was established and validated against the published experimental data. Eleven different scanning strategies were designed and simulated, considering variables such as scanning track length, direction, Out–In or In–Out strategy, start point, and interlayer variation. The results showed that scanning strategy, geometry, and layer number collectively affect temperature, melt pool, and stress outputs. For instance, starting scanning at a colder part of the powder layer could lead to a high peak temperature and low melt pool depth. A higher layer number generally results in lower cooling rate, a lower temperature gradient, a longer melt pool life, and larger melt pool dimensions. Changing the start point between scanning circulations helps mitigate detrimental residual stress. This work highlights the potential of analyzing various scanning strategy-related variables, which contributes to reducing trial-and-error tests and selecting optimal scanning strategies under different product quality requirements. This article can assist in the design of appropriate scanning strategies to prevent defects such as element loss due to evaporation, poor bonding, and deformation or cracking from high residual stress. Additionally, identifying stress concentration locations and understanding the effects of geometry and layer number on thermal and mechanical behaviors can assist in geometry design. |
| first_indexed | 2025-03-09T13:30:20Z |
| format | Journal Article |
| id | ntu-10356/180594 |
| institution | Nanyang Technological University |
| language | English |
| last_indexed | 2025-03-09T13:30:20Z |
| publishDate | 2024 |
| record_format | dspace |
| spelling | ntu-10356/1805942024-10-19T16:48:52Z The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting Yan, Zhiqiang Wu, Kaiwen Xiao, Zhongmin Hui, Jizhuang Lv, Jingxiang School of Mechanical and Aerospace Engineering Engineering Damping alloy Selective laser melting The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along which the laser head scans powders within given area, is crucial, but clearly defined criteria for scanning strategy design are lacking. In this study, a three-dimensional finite element model (FEM) of the SLM process for manufacturing a WE43 alloy component was established and validated against the published experimental data. Eleven different scanning strategies were designed and simulated, considering variables such as scanning track length, direction, Out–In or In–Out strategy, start point, and interlayer variation. The results showed that scanning strategy, geometry, and layer number collectively affect temperature, melt pool, and stress outputs. For instance, starting scanning at a colder part of the powder layer could lead to a high peak temperature and low melt pool depth. A higher layer number generally results in lower cooling rate, a lower temperature gradient, a longer melt pool life, and larger melt pool dimensions. Changing the start point between scanning circulations helps mitigate detrimental residual stress. This work highlights the potential of analyzing various scanning strategy-related variables, which contributes to reducing trial-and-error tests and selecting optimal scanning strategies under different product quality requirements. This article can assist in the design of appropriate scanning strategies to prevent defects such as element loss due to evaporation, poor bonding, and deformation or cracking from high residual stress. Additionally, identifying stress concentration locations and understanding the effects of geometry and layer number on thermal and mechanical behaviors can assist in geometry design. Published version This study is supported by the China Scholarship Council [CSC No. 202206560023] and Scientific Innovation Practice Project of Postgraduates of Chang’an University [300103724009]. 2024-10-14T05:57:11Z 2024-10-14T05:57:11Z 2024 Journal Article Yan, Z., Wu, K., Xiao, Z., Hui, J. & Lv, J. (2024). The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting. Materials, 17(12), 2912-. https://dx.doi.org/10.3390/ma17122912 1996-1944 https://hdl.handle.net/10356/180594 10.3390/ma17122912 2-s2.0-85197234947 12 17 2912 en Materials © 2024 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https:// creativecommons.org/licenses/by/ 4.0/). application/pdf |
| spellingShingle | Engineering Damping alloy Selective laser melting Yan, Zhiqiang Wu, Kaiwen Xiao, Zhongmin Hui, Jizhuang Lv, Jingxiang The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting |
| title | The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting |
| title_full | The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting |
| title_fullStr | The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting |
| title_full_unstemmed | The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting |
| title_short | The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting |
| title_sort | effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting |
| topic | Engineering Damping alloy Selective laser melting |
| url | https://hdl.handle.net/10356/180594 |
| work_keys_str_mv | AT yanzhiqiang theeffectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT wukaiwen theeffectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT xiaozhongmin theeffectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT huijizhuang theeffectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT lvjingxiang theeffectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT yanzhiqiang effectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT wukaiwen effectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT xiaozhongmin effectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT huijizhuang effectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting AT lvjingxiang effectofscanningstrategyonthethermalbehaviorandresidualstressdistributionofdampingalloysduringselectivelasermelting |