A Simulation Study on the Effect of Residual Stress on the Multi-Layer Selective Laser Melting Processes Considering Solid-State Phase Transformation
Abstract
:1. Introduction
2. Numerical Models in SLM Process
- (i)
- The vaporization and flow-induced temperature change of the liquid metal in the molten pool is ignored;
- (ii)
- The pores or the influence of gas during processing are not considered in the model;
- (iii)
- The creep-induced strain effects and solid-state phase transformation are neglected;
- (iv)
- The mechanical properties and stress-strain of the material change linearly in a small time interval.
- (v)
- Melting, solidification and particle-to-particle interactions of metal powder particles are not considered.
2.1. Heat Source Model
2.2. Transient Heat Transfer Analysis
2.3. Thermo-Mechanical Model
2.4. Material Properties
3. SLM Process Predictive Simulations
- (i)
- Begin calculation, the actual printed information and the finite element mesh intersecting data (event series) are sent to path-mesh intersecting data module.
- (ii)
- For each incremental step, the path-grid intersection information (the volume added to the grid, the location of the laser scan) is triggered during the printing time calculated by the current incremental step.
- (iii)
- Update each grid based on the information triggered by the current incremental step.
- (iv)
- The temperature field is solved, and the heat conduction and radiation are calculated based on the activated surface of the grid.
4. Results and Discussions
4.1. Temperature Distributions and Molten Pool Configurations
Effects of Laser Power
4.2. Residual Stresses Analysis
4.2.1. Solidification Process
4.2.2. Residual Stresses Analysis
4.2.3. Effects of Laser Power on Stress Field
4.2.4. Sensitivity Analysis of Grid Size
5. Conclusions
- (1)
- Due to the rapid solidification of melted powders, the residual stress along the laser scanning path produces a large stress gradient at the edge of the parts, which may lead to the maximum deformation along the printing direction appearing at the edge of the parts, and cause cracks.
- (2)
- The maximum tensile residual stress in the plane appears near the top layer, and decreases layer by layer with the increasing number of printing layers. At the interface between two continuous layers, the residual stress changes from tension to compression. The stress concentration occurred at the interface between the melt layer and the substrate may lead to warping deformation and even cracking.
- (3)
- The stress parallel to the scanning direction is the main stress causing cracks in SLM parts, as the stress parallel to the scanning direction is larger than the stress perpendicular to the scanning direction.
- (4)
- The toolpath-mesh intersection method can effectively predict the SLM process, but the grid size and incremental step of computing time have a great impact on the simulation results, and further improve the prediction accuracy of the SLM process is the direction that needs to be further investigated.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Process Parameters | Value | Unit or Notes |
---|---|---|
Power of heat source, P | 190/100 | W |
Scanning speed, v | 1000 | mm/s |
Scanning direction along x axis | 0.6 | mm |
Printing time for each layer | 4.8 | s |
Cooling time for each layer | 7.2 | s |
Layer thickness, h | 0.03 | mm |
Ambient/powder temperature, | 26 | C |
Substrate temperature, | 200 | C |
Parameters | Value | Unit |
---|---|---|
Latent heat of fusion | 2.86 × 10 | J/kg |
Solidus temperature | 1604 | C |
Liquidus temperature | 1650 | C |
Latent heat of vaporization | 9.83 × 10 | J/kg |
Liquidus temperature | 3290 | C |
Vaporized temperature | 3390 | C |
Density | 4420 | kg/m |
Emissivity | 0.25 | ∼ |
Convection Coefficient | 18 | W/(mC) |
Laser absorptivity | 50 | % |
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Li, X.; Zhang, M.; Qi, J.; Yang, Z.; Jiao, Z. A Simulation Study on the Effect of Residual Stress on the Multi-Layer Selective Laser Melting Processes Considering Solid-State Phase Transformation. Materials 2022, 15, 7175. https://doi.org/10.3390/ma15207175
Li X, Zhang M, Qi J, Yang Z, Jiao Z. A Simulation Study on the Effect of Residual Stress on the Multi-Layer Selective Laser Melting Processes Considering Solid-State Phase Transformation. Materials. 2022; 15(20):7175. https://doi.org/10.3390/ma15207175
Chicago/Turabian StyleLi, Xiao, Ming Zhang, Junfeng Qi, Zhengmao Yang, and Zhonghua Jiao. 2022. "A Simulation Study on the Effect of Residual Stress on the Multi-Layer Selective Laser Melting Processes Considering Solid-State Phase Transformation" Materials 15, no. 20: 7175. https://doi.org/10.3390/ma15207175