Abstract
As additive manufacturing (AM) continues to develop and become a standardized manufacturing method, there will be a continued need to provide in-situ monitoring during the manufacturing of polymer composite printed components. Thermal residual stress is a primary cause of failures such as interlayer disbonds or delamination, micro cracking, and dimensional instability, which can occur during or after the build. This study reports a novel digital image correlation (DIC) adaptation to monitor thermal residual stresses during the entire print process for large-scale AM. In this work, DIC has been investigated (a) by the natural speckle produced by the polymer surface for correlation, (b) to monitor AM build, and (c) to evaluate the effect of thermal residual stress on warpage of the printed component. The natural speckle pattern of the AM material resulted in a respectable 3.57% error compared to the traditional painted speckle pattern of 3.05% error. DIC measured a 190% increase in vertical displacement at the edge of the wall compared to the center, indicating warpage during AM. This work is a step towards a non-intrusive residual stress measuring technique using DIC for large-scale AM.
| Original language | English |
|---|---|
| Article number | 114545 |
| Journal | Composite Structures |
| Volume | 276 |
| DOIs | |
| State | Published - Nov 15 2021 |
Funding
Large-scale AM machine used in this research was sponsored by Cincinnati Inc., OH, USA. Feedstock materials used in this work were provided by Techmer PM., TN, USA. Notice of Copyright This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). We gratefully acknowledge the Institute of Advanced Composites Manufacturing Innovation (IACMI) and the Manufacturing Demonstration Facility (MDF), Oakridge National Laboratory (ORNL), TN, USA for financial and facilities support. We also appreciate Dr. Yanli Wang and Dr. Dayakar Penumadu for providing access to their Correlated Solutions VIC-2D software for the DIC analysis. Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Part of this work was funded in part by the Office of Energy Efficiency and Renewable Energy (EERE), U.S. Department of Energy, under Award Number DE-EE0006926.
| Funders | Funder number |
|---|---|
| Cincinnati Inc. | |
| Institute of Advanced Composites Manufacturing Innovation | |
| Manufacturing Demonstration Facility | |
| U.S. Department of Energy | |
| Advanced Manufacturing Office | DE-AC05-00OR22725 |
| Office of Energy Efficiency and Renewable Energy | DE-EE0006926 |
| Oak Ridge National Laboratory |
Keywords
- Additive manufacturing (AM)
- Composites
- Digital image correlation (DIC)
- Polymers
- Residual Stress
