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Open AccessArticle

A Novel Digital Design Approach for Metal Additive Manufacturing to Address Local Thermal Effects

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Theoretical & Applied Mechanics Group, Mechanical Engineering & Mechanics Department, Drexel University, 3141 Chestnut Street, Philadelphia, PA 19104, USA
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Multiscale Computational Mechanics and Biomechanics LAB, Mechanical Engineering & Mechanics Department, Drexel University, 3141 Chestnut Street, Philadelphia, PA 19104, USA
*
Authors to whom correspondence should be addressed.
Designs 2020, 4(4), 41; https://doi.org/10.3390/designs4040041
Received: 21 August 2020 / Revised: 23 September 2020 / Accepted: 24 September 2020 / Published: 1 October 2020
The reliability and performance qualification of additively manufactured metal parts is critical for their successful and safe use in engineering applications. In current powder-bed fusion type metal additive manufacturing processes, local thermal accumulations affect material microstructure features, overall part quality and integrity, as well as bulk mechanical behavior. To address such challenges, the investigation presented in this manuscript describes a novel digital design approach combining topology optimization, process simulations, and lattice size optimization to address local thermal effects caused during manufacturing. Specifically, lattices are introduced in regions of topology optimized geometries where local thermal accumulations are predicted using the process simulations with the overall goal to mitigate high thermal gradients. The results presented demonstrate that the proposed digital design approach reduces local thermal accumulations while achieving target mechanical performance metrics. A discussion on how post-manufacturing heat treatment effects could be also considered, as well as comments on the computational implementation of the proposed approach are provided. View Full-Text
Keywords: digital design; metal additive manufacturing; optimization; process simulation; thermal effects digital design; metal additive manufacturing; optimization; process simulation; thermal effects
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MDPI and ACS Style

I. Perumal, V.; R. Najafi, A.; Kontsos, A. A Novel Digital Design Approach for Metal Additive Manufacturing to Address Local Thermal Effects. Designs 2020, 4, 41.

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