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A Simulation Study on the Effect of Residual Stress on the Multi-Layer Selective Laser Melting Processes Considering
Xiao Li1, Ming Zhang1, Junfeng Qi1
1Beijing Spacecrafts, China Academy of Space Technology, Beijing 100094, China.
Materials (Basel, Switzerland)
|October 27, 2022
Summary
Selective laser melting (SLM) creates residual stresses and distortions. This study develops a thermo-mechanical framework to predict and analyze these issues, offering insights into the molten pool
Area of Science:
- Additive Manufacturing
- Materials Science
- Computational Mechanics
Background:
- Selective Laser Melting (SLM) involves complex thermal-mechanical phenomena.
- High residual stresses in SLM can cause structural warping, cracking, and failure.
- Understanding molten pool dynamics is crucial for predicting SLM outcomes.
Purpose of the Study:
- To establish a comprehensive thermo-mechanical framework for SLM.
- To predict temperature evolution, molten pool characteristics, and residual stresses.
- To analyze the impact of process parameters on SLM outcomes.
Main Methods:
- Utilized a toolpath-mesh intersection method for simulation.
- Developed a framework to model thermal and mechanical behaviors during SLM.
- Investigated the influence of laser power, process parameters, and mesh size.
Main Results:
- Identified stress concentration at the melt layer-substrate interface.
- Demonstrated that high residual stresses lead to warping deformation.
- Quantified the effects of varying laser power and mesh size on thermal-mechanical response.
Conclusions:
- The developed thermo-mechanical framework accurately predicts SLM phenomena.
- Provides a novel method for understanding residual stress and distortion mechanisms.
- Offers insights for optimizing SLM process parameters to mitigate defects.
Keywords:
additive manufacturingfinite element analysislaser depositionresidual stressthermo-mechanical modelingMore Related Videos
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