Correlations of interlayer time with distortion of large Ti-6Al-4V components in laser metal deposition with wire

Y. S. Leea; Y. Bandaria; S. Simunovic; B. Richardsona; M. M. Kirkaa

Correlations of interlayer time with distortion of large Ti-6Al-4V components in laser metal deposition with wire

Y. S. Leea, Y. Bandaria, S. Simunovic, B. Richardsona, M. M. Kirkaa

Multiscale Materials

Research output: Contribution to conference › Paper › peer-review

4 Scopus citations

Abstract

Laser metal deposition with wire (LMD-w) is one of the emerging additive manufacturing (AM) technologies for large-scale aerospace components due to high deposition rates and material efficiency. However, it often results in undesired stresses and distortions due to non-uniform expansion and contraction of material during printing. Controlling inter-layer time, preheating, and clamping are the effective methods to mitigate the thermally induced stress and deformation. In this study, the effect of inter-layer cooling time on part distortion is investigated using a finite element method (FEM). The model accounts for actual tool paths, power, and cooling conditions. The results show that the model effectively captures the fluctuation of the Ti-6Al-4V plate during printing. Also, it shows an asymmetric distortion on the plate edges. Ultimately, the sequentially coupled thermal-stress simulation provided a quantitative understanding of the inter-layer cooling time on titanium plate distortion for the large-scale LMD-w process.

Original language	English
Pages	606-622
Number of pages	17
State	Published - 2020
Event	29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018 - Austin, United States Duration: Aug 13 2018 → Aug 15 2018

Conference

Conference	29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018
Country/Territory	United States
City	Austin
Period	08/13/18 → 08/15/18

Funding

The research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office under contract DE-AC05- 00OR22725 with UT-Battelle, LLC. This work is also supported in part by Cooperative Research and Development Agreement with GKN Aerospace, under contract No. NFE-15-05725. The research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office under contract DE-AC05-00OR22725 with UT-Battelle, LLC. This work is also supported in part by Cooperative Research and Development Agreement with GKN Aerospace, under contract No. NFE-15-05725. 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).

Funders	Funder number
US Department of Energy
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725, NFE-15-05725
Office of Energy Efficiency and Renewable Energy

Keywords

Additive manufacturing
Distortion
Finite element method
Inter-layer time
LMD-wire
Plate oscillation
Ti-6Al-4V

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Cite this

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title = "Correlations of interlayer time with distortion of large Ti-6Al-4V components in laser metal deposition with wire",

abstract = "Laser metal deposition with wire (LMD-w) is one of the emerging additive manufacturing (AM) technologies for large-scale aerospace components due to high deposition rates and material efficiency. However, it often results in undesired stresses and distortions due to non-uniform expansion and contraction of material during printing. Controlling inter-layer time, preheating, and clamping are the effective methods to mitigate the thermally induced stress and deformation. In this study, the effect of inter-layer cooling time on part distortion is investigated using a finite element method (FEM). The model accounts for actual tool paths, power, and cooling conditions. The results show that the model effectively captures the fluctuation of the Ti-6Al-4V plate during printing. Also, it shows an asymmetric distortion on the plate edges. Ultimately, the sequentially coupled thermal-stress simulation provided a quantitative understanding of the inter-layer cooling time on titanium plate distortion for the large-scale LMD-w process.",

keywords = "Additive manufacturing, Distortion, Finite element method, Inter-layer time, LMD-wire, Plate oscillation, Ti-6Al-4V",

author = "Leea, {Y. S.} and Y. Bandaria and S. Simunovic and B. Richardsona and Kirkaa, {M. M.}",

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language = "English",

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Leea, YS, Bandaria, Y, Simunovic, S, Richardsona, B & Kirkaa, MM 2020, 'Correlations of interlayer time with distortion of large Ti-6Al-4V components in laser metal deposition with wire', Paper presented at 29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018, Austin, United States, 08/13/18 - 08/15/18 pp. 606-622.

Correlations of interlayer time with distortion of large Ti-6Al-4V components in laser metal deposition with wire. / Leea, Y. S.; Bandaria, Y.; Simunovic, S. et al.
2020. 606-622 Paper presented at 29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018, Austin, United States.

Research output: Contribution to conference › Paper › peer-review

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T1 - Correlations of interlayer time with distortion of large Ti-6Al-4V components in laser metal deposition with wire

AU - Leea, Y. S.

AU - Bandaria, Y.

AU - Simunovic, S.

AU - Richardsona, B.

AU - Kirkaa, M. M.

N1 - Publisher Copyright: © Solid Freeform Fabrication 2018: Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018. All Rights Reserved.

PY - 2020

Y1 - 2020

N2 - Laser metal deposition with wire (LMD-w) is one of the emerging additive manufacturing (AM) technologies for large-scale aerospace components due to high deposition rates and material efficiency. However, it often results in undesired stresses and distortions due to non-uniform expansion and contraction of material during printing. Controlling inter-layer time, preheating, and clamping are the effective methods to mitigate the thermally induced stress and deformation. In this study, the effect of inter-layer cooling time on part distortion is investigated using a finite element method (FEM). The model accounts for actual tool paths, power, and cooling conditions. The results show that the model effectively captures the fluctuation of the Ti-6Al-4V plate during printing. Also, it shows an asymmetric distortion on the plate edges. Ultimately, the sequentially coupled thermal-stress simulation provided a quantitative understanding of the inter-layer cooling time on titanium plate distortion for the large-scale LMD-w process.

AB - Laser metal deposition with wire (LMD-w) is one of the emerging additive manufacturing (AM) technologies for large-scale aerospace components due to high deposition rates and material efficiency. However, it often results in undesired stresses and distortions due to non-uniform expansion and contraction of material during printing. Controlling inter-layer time, preheating, and clamping are the effective methods to mitigate the thermally induced stress and deformation. In this study, the effect of inter-layer cooling time on part distortion is investigated using a finite element method (FEM). The model accounts for actual tool paths, power, and cooling conditions. The results show that the model effectively captures the fluctuation of the Ti-6Al-4V plate during printing. Also, it shows an asymmetric distortion on the plate edges. Ultimately, the sequentially coupled thermal-stress simulation provided a quantitative understanding of the inter-layer cooling time on titanium plate distortion for the large-scale LMD-w process.

KW - Additive manufacturing

KW - Distortion

KW - Finite element method

KW - Inter-layer time

KW - LMD-wire

KW - Plate oscillation

KW - Ti-6Al-4V

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M3 - Paper

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T2 - 29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018

Y2 - 13 August 2018 through 15 August 2018

ER -

Correlations of interlayer time with distortion of large Ti-6Al-4V components in laser metal deposition with wire

Abstract

Conference

Funding

Keywords

UN SDGs

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