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- Hassila Karlsson, Carl Johan, et al.
(författare)
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Influence of scanning strategy on residual stresses in laser powder bed fusion manufactured alloy 718: Modeling and experiments
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Annan publikation (övrigt vetenskapligt/konstnärligt)abstract
- Residual stresses are a known phenomenon in additively manufactured materials. The residual stresses increase the risk of cracks, limit in-service performance, and distort printed parts. In this work, thermo-mechanical finite element models using the hatch-by-hatch and layer-by-layer approach, and the inherent strain method has been developed and applied to predict the effects of different scanning strategies on the deflection and the residual stresses of two PBF-LB processed geometries. To account for viscoplasticty and relaxation effects, a mechanism-based material model have been implemented and used. It is shown that the hatch-by-hatch approach and inherent strain method both successfully predicted the experimentally measured deflections of the first geometry, which was printed using different scanning directions. To predict the stress field experimentally, high-energy synchrotron measurements have been used to. The thermo-mechanical models and the inherent strain method both captures the trend of experimentally measured residual stress fields, although with an overall underprediction. The predictions of the models were evaluated, and their accuracy discussed in terms of physical aspects of the Powder Bed Fusion – Laser Beam process.
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- Lindgren, Lars-Erik, et al.
(författare)
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Thermal stresses and computational welding mechanics
- 2019
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Ingår i: Journal of thermal stresses. - : Taylor & Francis. - 0149-5739 .- 1521-074X. ; 42:1, s. 107-121
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Tidskriftsartikel (refereegranskat)abstract
- Computational welding mechanics (CWM) have a strong connection to thermal stresses, as they are one of the main issues causing problems in welding. The other issue is the related welding deformations together with existing microstructure. The paper summarizes the important models related to prediction of thermal stresses and the evolution of CWM models in order to manage the large amount of ‘welds’ in additive manufacturing.
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- Lindwall, Johan, et al.
(författare)
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Efficiency and Accuracy in Thermal Simulation of Powder Bed Fusion of Bulk Metallic Glass
- 2018
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Ingår i: JOM. - : Springer. - 1047-4838 .- 1543-1851. ; 70:8, s. 1598-1603
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Tidskriftsartikel (refereegranskat)abstract
- Additive manufacturing by powder bed fusion processes can be utilized to create bulk metallic glass as the process yields considerably high cooling rates. However, there is a risk that reheated material set in layers may become devitrified, i.e., crystallize. Therefore, it is advantageous to simulate the process to fully comprehend it and design it to avoid the aforementioned risk. However, a detailed simulation is computationally demanding. It is necessary to increase the computational speed while maintaining accuracy of the computed temperature field in critical regions. The current study evaluates a few approaches based on temporal reduction to achieve this. It is found that the evaluated approaches save a lot of time and accurately predict the temperature history.
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- Malmelöv, Andreas, et al.
(författare)
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History Reduction by Lumping for Time-Efficient Simulation of Additive Manufacturing
- 2020
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Ingår i: Metals. - : MDPI. - 2075-4701. ; 10:1
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Tidskriftsartikel (refereegranskat)abstract
- Additive manufacturing is the process by which material is added layer by layer. In most cases, many layers are added, and the passes are lengthy relative to their thicknesses and widths. This makes finite element simulations of the process computationally demanding owing to the short time steps and large number of elements. The classical lumping approach in computational welding mechanics, popular in the 80s, is therefore, of renewed interest and is evaluated in this work. The method of lumping means that welds are merged. This allows fewer time steps and a coarser mesh. It was found that the computation time can be reduced considerably, with retained accuracy for the resulting temperatures and deformations. The residual stresses become, to a certain degree, smaller. The simulations were validated against a directed energy deposition (DED) experiment with alloy 625.
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- Malmelöv, Andreas
(författare)
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History Reduction Techniques for Simulation of Additive Manufacturing and Physically based Material Modeling
- 2020
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- In this thesis, finite element (FE) simulations of additive manufacturing (AM) and physically based material modeling are presented. AM is a process where the component is built layer-wise. The material undergoes repeated heating and cooling cycles when layers are added, which may result in undesired deformation and residual stress in the built component. The choice of process parameters and scan strategy affect the resulting residual stress. Simulations can be used to support the experimental determination of process parameters and scan strategy. AM processes often comprise many added layers, and the passes are lengthy relative to their thicknesses and widths. This makes the FE simulations computationally expensive, with many elements and time steps. In this work, AM processes have been simulated with the FE-method using a lumping technique. This technique allows fewer time steps and a coarser mesh. Thermal behavior, deformation, and residual stresses have been simulated and compared with experiments. The simulations show that, by using the lumping technique, the computational effort can be reduced significantly with retained accuracy for the resulting temperature and deformations. The residual stresses become somewhat smaller. Alloy 625 is a nickel-based superalloy used in high-temperature applications owing to the hightemperature strength. The material is difficult to manufacture by conventional machining owing to excessive tool wear and low material removal rates. Thus alloy 625 is a material appropriate for the AM technology with its near-net shape potential. An existing, physically based flow stress model has been further developed to fit the mechanisms typical for alloy 625. This model gives an accurate mechanical behavior and capture viscoplasticity, creep, and relaxation. The physically based model has been calibrated versus compression tests and validated with a stress relaxation test performed in a Gleeble 3800 machine. The predicted relaxation was in good agreement with the measured relaxation. The usage of this kind of material model is expected to improve the prediction of the material behavior during the AM process and, thereby, the overall prediction of the AM process.
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- Malmelöv, Andreas, et al.
(författare)
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Mechanism based flow stress model for Alloy 625 and Alloy 718
- 2020
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Ingår i: Materials. - : MDPI. - 1996-1944. ; 13:24
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Tidskriftsartikel (refereegranskat)abstract
- To predict the final geometry in thermo-mechanical processes, the use of modeling tools is of great importance. One important part of the modeling process is to describe the response correctly. A previously published mechanism-based flow stress model has been further developed and adapted for the nickel-based superalloys, alloy 625, and alloy 718. The updates include the implementation of a solid solution strengthening model and a model for high temperature plasticity. This type of material model is appropriate in simulations of manufacturing processes where the material undergoes large variations in strain rates and temperatures. The model also inherently captures stress relaxation. The flow stress model has been calibrated using compression strain rate data ranging from 0.01 to 1 s−1 with a temperature span from room temperature up to near the melting temperature. Deformation mechanism maps are also constructed which shows when the different mechanisms are dominating. After the model has been calibrated, it is validated using stress relaxation tests. From the parameter optimization, it is seen that many of the parameters are very similar for alloy 625 and alloy 718, although it is two different materials. The modeled and measured stress relaxation are in good agreement.
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| 9. |
- Malmelöv, Andreas, et al.
(författare)
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Numerical modeling and synchrotron diffraction measurements of residual stresses in laser powder bed fusion manufactured alloy 625
- 2022
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Ingår i: Materials & design. - : Elsevier. - 0264-1275 .- 1873-4197. ; 216
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Tidskriftsartikel (refereegranskat)abstract
- Residual stresses in metal additive manufactured components are a well-known problem. It causes distortion of the samples when removing them from the build plate, as well as acting detrimental with regard to fatigue. The understanding of how residual stresses in a printed sample are affected by process parameters is crucial to allow manufacturers to tune their process parameters, or the design of their component, to limit the negative influence of residual stresses. In this paper, residual stresses in additive manufactured samples are simulated using a thermo-mechanical finite element model. The elasto-plastic behavior of the material is described by a mechanism-based material model that accounts for microstructural and relaxation effects. The heat source in the finite element model is calibrated by fitting the model to experimental data. The residual stress field from the finite element model is compared with experimental results attained from synchrotron X-ray diffraction measurements. The results from the model and measurement give the same trend in the residual stress field. In addition, it is shown that there is no significant difference in trend and magnitude of the resulting residual stresses for an alternation in laser power and scanning speed.
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