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A Hybrid Method for the Online Evaluation of Stress Fields in Metal Additive Manufacturing

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Abstract

Background

Metal additive manufacturing has extensive application prospects in the aerospace, precision instrument, and biomedical fields, etc. However, the low manufacturing quality of key components is a bottleneck restricting the further development and application of this technology. Because of the extremely complex manufacturing environment, a real-time and online monitoring technology for the manufacturing quality remains lacking.

Objective

For laser engineered net shaping (LENS), a mainstream technology of metal additive manufacturing, a hybrid method for the online evaluation of stress fields during laser cladding is developed in this paper that combines the real-time measured temperature field, three-dimensional deformation field and finite element method.

Methods

The proposed method first designed the synchronous measurement optical paths of the temperature field and three-dimensional deformation field of the substrate, and the positions of the temperature and deformation field images were matched. A finite element model was established based on the printing parameters such as the layer thickness and printing speed, and the temperature field and three-dimensional deformation field synchronously measured at each moment were incorporated into the model as boundary conditions to obtain the deformation and stress information inside the model.

Results

We compared the stress field obtained at the end of printing with the XRD (X-ray diffraction) measurement results to verify the effectiveness of the proposed method. The proposed method can obtain the three-dimensional stress distribution and evolution of the substrate and printed component.

Conclusion

The proposed method can realize the online characterization of the three-dimensional stress field in the LENS printing process and provide important experimental guidance and data for the quality control of 3D printing.

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Acknowledgements

This work was financially supported by the National Key Research and Development Program of China (Grant No.2017YFB1103900), National Natural Science Foundation of China(11972084),National Science and Technology Major Project (2017-VI-0003-0073),Beijing Institute of Spacecraft Environment Engineering (CAST-BISEE2019-010), and Beijing Natural Science Foundation (1192014).

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Author notes

  1. G.Z. Zeng and R.L. Zu contributed equally to this work.

Authors and Affiliations

  1. School of Aerospace Engineering, Beijing Institute of Technology, Beijing, 100081, People’s Republic of China

    G. Z. Zeng, R. L. Zu, J. Y. Zhao & Z. W. Liu

  2. Beijing Institute of Spacecraft Environment Engineering, Beijing, 100020, People’s Republic of China

    D. L. Wu

  3. Department of Engineering Mechanics, AML, Tsinghua University, Beijing, 100084, People’s Republic of China

    W. X. Shi & H. M. Xie

  4. Beijing Institute of Structure & Environment Engineering, Beijing, 100076, People’s Republic of China

    J. F. Zhou

  5. School of Power and Mechanical Engineering, Wuhan University, Wuhan, 430072, People’s Republic of China

    S. Liu

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  1. G. Z. Zeng
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Correspondence to Z. W. Liu.

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Zeng, G.Z., Zu, R.L., Wu, D.L. et al. A Hybrid Method for the Online Evaluation of Stress Fields in Metal Additive Manufacturing. Exp Mech 61, 1261–1270 (2021). https://doi.org/10.1007/s11340-021-00735-4

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