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Numerical Modelling and Quality Assessment of Additively Manufactured Metallic Components

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 June 2022) | Viewed by 1667

Special Issue Editors


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Guest Editor
Department of Applied Physics and Materials Engineering, E.T.S. Ingenieros Industriales, Polytechnical University of Madrid, 28040 Madrid, Spain
Interests: laser shock processing; laser additive manufacturing; materials characterization
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Guest Editor
Department of Applied Physics and Materials Engineering, E.T.S. Ingenieros Industriales, Polytechnical University of Madrid, Madrid, Spain
Interests: laser additive manufacturing; surface treatment; metallurgy

Special Issue Information

Dear Colleagues,

Additive Manufacturing (AM) of metallic components is attracting enormous interest from academics and industrials given its potential for advanced applications in different fields such as biomedical implants, aerospace, automotive, energy, etc. Additive Manufacturing offers well-known features that are not reachable through conventional manufacturing technologies such as machining or casting. Some of the most appreciated advantages of AM with metallic components can be found in situations where a high degree of customization is required, such as in complex geometries or lightened components, where, in the latter, the mechanical response of the lightened part is achieved thanks to an engineered non-trivial structure.  From the management point of view, AM of metallic parts also offers significant benefits, accelerating the development of new products, favoring, in this way, their quick launch into the market.

One of the main limiting factors for the full development of AM applications within industry is the high degree of complexity of the physics inherent to the process. For example, the consolidation of the metallic powder involves a series of phenomena concerning phase change, fluid dynamics, thermal balance with very high heating and cooling rates, etc. All these concurrent phenomena determine fundamental microstructural characteristics of the consolidated material concerning the shape, size, and orientation of the metallographic grains or the size and distribution of pores, which, in turn, determine the mechanical response of the sample, affecting the quality of the manufactured parts.

Numerical Modelling and, in general, quality assessment techniques offer powerful tools to tackle the complex phenomena influencing the dynamics of the microstructure development during the consolidation of the material in metal AM processes. The understanding of these complex relations allows users and researchers on AM systems to determine the mechanisms that connect the process parameters and the microstructure of the consolidated material, promoting, in this way, the successful application of these technologies.

Prof. Dr. José L. Ocaña
Dr. Francisco Cordovilla
Guest Editors

Manuscript Submission Information

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Keywords

  • additive manufacturing
  • direct energy deposition
  • direct laser melting
  • electron beam melting
  • selective laser melting
  • metallic powder
  • numerical simulation
  • solidification
  • microstructure
  • metallurgy
  • dendritic growth
  • columnar growth
  • residual stresses
  • steel
  • titanium
  • aluminium

Published Papers (1 paper)

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Research

19 pages, 6066 KiB  
Article
Conventional Meso-Scale and Time-Efficient Sub-Track-Scale Thermomechanical Model for Directed Energy Deposition
by Vaibhav Nain, Thierry Engel, Muriel Carin and Didier Boisselier
Materials 2022, 15(12), 4093; https://doi.org/10.3390/ma15124093 - 09 Jun 2022
Cited by 2 | Viewed by 1361
Abstract
Thermally-induced distortion and residual stresses in parts fabricated by the additive manufacturing (AM) process can lead to part rejection and failure. Still, the understanding of thermo–mechanical behavior induced due to the process physics in AM process is a complex task that depends upon [...] Read more.
Thermally-induced distortion and residual stresses in parts fabricated by the additive manufacturing (AM) process can lead to part rejection and failure. Still, the understanding of thermo–mechanical behavior induced due to the process physics in AM process is a complex task that depends upon process and material parameters. In this work, a 3D thermo-elasto-plastic model is proposed to predict the thermo–mechanical behavior (thermal and distortion field) in the laser-directed energy deposition (LDED) process using the finite element method (FEM). The predicted thermo–mechanical responses are compared to stainless steel 316L (SS 316L) deposition, with single and double bead 42-layer wall samples subject to different inter-layer dwell times, which govern the thermal response of deposited parts in LDED. In this work, the inter-layer dwell times used in experiments vary from 0 to 10 s. Based on past research into the LDED process, it is assumed that fusion and thermal cycle-induced annealing leads to stress relaxation in the material, and is accounted for in the model by instantaneously removing stresses beyond an inversely calibrated relaxation temperature. The model predicts that, for SS 316L, an increase in dwell time leads to a decrease in in situ and post-process distortion values. Moreover, increasing the number of beads leads to an increase in in situ and post-process distortion values. The calibrated numerical model’s predictions are accurate when compared with in situ and post-process experimental measurements. Finally, an elongated ellipsoid heat source model is proposed to speed up the simulation. Full article
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