Prediction of Behaviour of Thin-Walled DED-Processed Structure: Experimental-Numerical Approach.

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Additive Manufacturing

Background:

• Additive manufacturing (AM), specifically directed energy deposition (DED), is increasingly standard but lacks data on complex structure behavior.
• Understanding the structural performance, including flow curves and local damage, of DED parts is vital, especially for thin, as-deposited components.

Purpose of the Study:

• To predict the static loading behavior of thin-walled structures produced by DED using finite element analysis (FEA).
• To compare the mechanical performance of machined versus as-deposited miniaturized samples from these structures.

Main Methods:

• Finite Element Analysis (FEA) for predicting structural behavior.
• Hybrid experimental-numerical approach utilizing uncoupled damage models.
• Microstructural and hardness examinations to understand structural performance.

Main Results:

• FEA was used to predict the static loading behavior of DED-processed thin-walled structures.
• Mechanical performance differences between partly machined, fully machined, and as-deposited samples were evaluated.
• Microstructure and hardness analyses provided insights into the material's behavior under load.

Conclusions:

• The study provides a predictive model for the mechanical behavior of DED-manufactured thin-walled structures.
• Understanding the impact of post-processing (machining) on mechanical properties is essential for component design.
• This research contributes to the knowledge base for applying DED in critical industrial applications.