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Article

Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion

1
International Center for Numerical Methods in Engineering, Technical University of Catalonia, 08034 Barcelona, Spain
2
State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an 710072, China
*
Authors to whom correspondence should be addressed.
Academic Editor: Mohammad Jahazi
Metals 2021, 11(5), 686; https://doi.org/10.3390/met11050686
Received: 23 March 2021 / Revised: 16 April 2021 / Accepted: 20 April 2021 / Published: 22 April 2021
(This article belongs to the Special Issue Material Modeling in Multiphysics Simulation)
Thin-walled structures are of great interest because of their use as lightweight components in aeronautical and aerospace engineering. The fabrication of these components by additive manufacturing (AM) often produces undesired warpage because of the thermal stresses induced by the manufacturing process and the components’ reduced structural stiffness. The objective of this study is to analyze the distortion of several thin-walled components fabricated by Laser Powder Bed Fusion (LPBF). Experiments are performed to investigate the sensitivity of the warpage of thin-walled structures fabricated by LPBF to different design parameters such as the wall thickness and the component height in several open and closed shapes. A 3D-scanner is used to measure the residual distortions in terms of the out-of-plane displacement. Moreover, an in-house finite element software is firstly calibrated and then used to enhance the original design in order to minimize the warpage induced by the LPBF printing process. The outcome of this shows that open geometries are more prone to warping than closed ones, as well as how vertical stiffeners can mitigate component warpage by increasing stiffness. View Full-Text
Keywords: additive manufacturing; laser powder bed fusion; thin-walled structures; warpage; finite element analysis additive manufacturing; laser powder bed fusion; thin-walled structures; warpage; finite element analysis
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MDPI and ACS Style

Lu, X.; Chiumenti, M.; Cervera, M.; Tan, H.; Lin, X.; Wang, S. Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion. Metals 2021, 11, 686. https://doi.org/10.3390/met11050686

AMA Style

Lu X, Chiumenti M, Cervera M, Tan H, Lin X, Wang S. Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion. Metals. 2021; 11(5):686. https://doi.org/10.3390/met11050686

Chicago/Turabian Style

Lu, Xufei, Michele Chiumenti, Miguel Cervera, Hua Tan, Xin Lin, and Song Wang. 2021. "Warpage Analysis and Control of Thin-Walled Structures Manufactured by Laser Powder Bed Fusion" Metals 11, no. 5: 686. https://doi.org/10.3390/met11050686

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