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Analysis of the Part Distortions for Inconel 718 SLM: A Case Study on the NIST Test Artifact
Silvia Martínez1, Naiara Ortega1, Diego Celentano2
1Department of Mechanical Engineering, Aeronautics Advanced Manufacturing Center (CFAA), Faculty of Engineering of Bilbao, Alameda de Urquijo s/n, 48013 Bilbao, Spain.
Materials (Basel, Switzerland)
|November 14, 2020
Summary
Selective Laser Melting (SLM) of Inconel 718 parts causes geometric distortion due to thermal gradients. Feature position and laser strategy significantly impact part accuracy, crucial for aerospace applications.
Area of Science:
- Materials Science and Engineering
- Additive Manufacturing
- Mechanical Engineering
Background:
- Selective Laser Melting (SLM) is a key additive manufacturing process for high-performance alloys like Inconel 718.
- Geometric accuracy and distortion are critical challenges in SLM, particularly for aerospace components requiring high strength-to-weight ratios.
- Understanding the factors influencing distortion is essential for process optimization and reliable part production.
Purpose of the Study:
- To evaluate the geometric distortion and misalignment of a standard National Institute of Standards and Technology (NIST) test artifact manufactured using SLM.
- To investigate the influence of support structures and layer-by-layer manufacturing on part distortion.
- To correlate manufacturing parameters, specifically laser path strategy and feature position, with observed geometrical inaccuracies.
Main Methods:
- Manufacturing of NIST test artifacts in Inconel 718 using Selective Laser Melting (SLM) with varying support configurations.
- Geometrical metrology using a Coordinate Measuring Machine (CMM) to quantify misalignment and distortion.
- Numerical simulation to determine thermal gradients and residual stress patterns induced by the SLM process.
Main Results:
- The laser path strategy was found to induce thermal gradients, leading to significant geometrical distortions in the SLM-manufactured parts.
- Feature position and laser strategy were identified as critical factors influencing the degree of distortion.
- Thermal cycles and residual stresses directly impact the final geometry of the Inconel 718 artifact.
Conclusions:
- The study confirms that laser path strategy and feature placement are primary drivers of geometric distortion in SLM of Inconel 718.
- Residual stresses and thermal gradients significantly affect part accuracy, necessitating careful process control for aerospace applications.
- Optimizing SLM parameters is crucial for achieving desired dimensional stability in high-performance alloy components.
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