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Process chain simulation of laser powder bed fusion including heat treatment and surface hardening
CIRP Journal of Manufacturing Science and Technology ( IF 4.6 ) Pub Date : 2021-01-22 , DOI: 10.1016/j.cirpj.2021.01.006
J.M. O’Brien , S. Montgomery , A. Yaghi , S.M. Afazov

Additive manufacturing (AM) has enabled the creation of geometrically complex parts for a range of industries. However, the nature of AM often requires multiple post processing techniques to be carried out to reach the desired material properties or required surface finish. This often involves heat treatment (HT), shot peening (SP) or laser shock peening (LSP). To date, hardly any process chain modelling has been carried out on manufacturing applications with AM. This investigation focuses on the finite element (FE) modelling of the complete manufacturing process chain of an AM impeller made of IN718, including the AM, HT, LSP and SP processes. The particular AM process applied to build the impeller is laser powder bed fusion (L-PBF). Each FE process is validated individually against experimental data before being applied to the impeller process chain. The validated data from each process is mapped to the next process in the chain to investigate the combined effects of manufacturing and post processing techniques. Results have shown that high tensile residual stresses induced by AM can be reduced by approximately 75% by applying HT. SP and LSP processes can further modify remaining tensile residual stresses after HT by inducing a layer of compressive stresses at the surface. In summary, this research work has demonstrated that the simulation of AM process chains using finite element techniques is sufficiently mature to support the product and process development of industrial AM components.



中文翻译:

激光粉末床熔合的工艺链模拟,包括热处理和表面硬化

增材制造(AM)使得能够为一系列行业创建几何形状复杂的零件。但是,AM的性质通常需要执行多种后处理技术才能达到所需的材料性能或所需的表面光洁度。这通常涉及热处理(HT),喷丸处理(SP)或激光冲击喷丸处理(LSP)。迄今为止,几乎没有在带有AM的制造应用程序上进行任何过程链建模。这项研究的重点是由IN718制成的AM叶轮的完整制造过程链的有限元(FE)建模,包括AM,HT,LSP和SP过程。用于制造叶轮的特定AM工艺是激光粉末床熔合(L-PBF)。在将每个有限元流程应用于叶轮流程链之前,均会根据实验数据对它们进行单独验证。来自每个过程的经过验证的数据将映射到链中的下一个过程,以研究制造和后处理技术的综合效果。结果表明,通过施加HT,由AM引起的高拉伸残余应力可以降低约75%。SP和LSP工艺可以通过在表面产生一层压应力来进一步修改HT之后的残余拉伸残余应力。总而言之,这项研究工作表明,使用有限元技术对AM过程链进行仿真已经足够成熟,可以支持工业AM组件的产品和过程开发。来自每个过程的经过验证的数据将映射到链中的下一个过程,以研究制造和后处理技术的综合效果。结果表明,通过施加HT,由AM引起的高拉伸残余应力可以降低约75%。SP和LSP工艺可以通过在表面产生一层压应力来进一步修改HT之后的残余拉伸残余应力。总而言之,这项研究工作表明,使用有限元技术对AM过程链进行仿真已经足够成熟,可以支持工业AM组件的产品和过程开发。来自每个过程的经过验证的数据将映射到链中的下一个过程,以研究制造和后处理技术的综合效果。结果表明,通过施加HT,由AM引起的高拉伸残余应力可以降低约75%。SP和LSP工艺可以通过在表面产生一层压应力来进一步修改HT之后的残余拉伸残余应力。总而言之,这项研究工作表明,使用有限元技术对AM过程链进行仿真已经足够成熟,可以支持工业AM组件的产品和过程开发。SP和LSP工艺可以通过在表面产生一层压应力来进一步修改HT之后的残余拉伸残余应力。总而言之,这项研究工作表明,使用有限元技术对AM过程链进行仿真已经足够成熟,可以支持工业AM组件的产品和过程开发。SP和LSP工艺可以通过在表面产生一层压应力来进一步修改HT之后的残余拉伸残余应力。总而言之,这项研究工作表明,使用有限元技术对AM过程链进行仿真已经足够成熟,可以支持工业AM组件的产品和过程开发。

更新日期:2021-01-22
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