Distortion Prediction in Inconel-718 Part Fabricated through LPBF by Using Homogenized Support Properties from...

Area of Science:

• Materials Science
• Mechanical Engineering
• Computational Modeling

Background:

• Laser Powder-Bed Fusion (LPBF) manufacturing creates complex geometries but faces challenges like residual stress and distortion.
• Lattice structures are crucial for supporting overhangs and mitigating distortion in LPBF parts.
• Simulating the distortion of complex lattice supports requires substantial computational resources.

Purpose of the Study:

• To develop a computational effort reduction strategy for predicting distortion in LPBF parts.
• To replace complex lattice support geometry with a homogenized model based on experimental data.
• To improve the efficiency of distortion prediction simulations in additive manufacturing.

Main Methods:

• Experimentally determined mechanical properties of additively manufactured Inconel 718 lattices were used.
• A power-law relationship was established for the mechanical properties of various lattice topologies.
• This model was applied for homogenization in distortion prediction simulations, validated with a cantilever model.

Main Results:

• The homogenization technique significantly increased computational speed by 6-7 times.
• The accuracy of distortion prediction was maintained despite the reduction in computational effort.
• A validated power-law model effectively represents the mechanical behavior of lattice supports.

Conclusions:

• Homogenization of lattice supports is an effective strategy to reduce computational cost in LPBF distortion simulations.
• The proposed method offers a practical approach for optimizing simulation workflows in additive manufacturing.
• Accurate prediction of distortion can be achieved more efficiently, aiding in the production of high-quality parts.