Computational modeling of residual stress formation during the electron beam melting process for Inconel 718

P. Prabhakar, W. J. Sames, R. Dehoff, S. S. Babu

    Research output: Contribution to journalArticlepeer-review

    183 Scopus citations

    Abstract

    A computational modeling approach to simulate residual stress formation during the electron beam melting (EBM) process within the additive manufacturing (AM) technologies for Inconel 718 is presented in this paper. The EBM process has demonstrated a high potential to fabricate components with complex geometries, but the resulting components are influenced by the thermal cycles observed during the manufacturing process. When processing nickel based superalloys, very high temperatures (approx. 1000 °C) are observed in the powder bed, base plate, and build. These high temperatures, when combined with substrate adherence, can result in warping of the base plate and affect the final component by causing defects. It is important to have an understanding of the thermo-mechanical response of the entire system, that is, its mechanical behavior towards thermal loading occurring during the EBM process prior to manufacturing a component. Therefore, computational models to predict the response of the system during the EBM process will aid in eliminating the undesired process conditions, a priori, in order to fabricate the optimum component. Such a comprehensive computational modeling approach is demonstrated to analyze warping of the base plate, stress and plastic strain accumulation within the material, and thermal cycles in the system during different stages of the EBM process.

    Original languageEnglish
    Pages (from-to)83-91
    Number of pages9
    JournalAdditive Manufacturing
    Volume7
    DOIs
    StatePublished - Jul 1 2015

    Funding

    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 . This research was also supported by fellowship funding received from the U.S. Department of Energy, Office of Nuclear Energy, Nuclear Energy University Programs. 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, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes.

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