Abstract
Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and effciency and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180° rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.
Original language | English |
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Article number | 5115 |
Journal | Applied Sciences (Switzerland) |
Volume | 9 |
Issue number | 23 |
DOIs | |
State | Published - Dec 1 2019 |
Funding
The authors like to acknowledge the contribution of the extended Oak Ridge National Laboratory and GKN Aerospace teams, particularly those of Abigail Barnes of ORNL and Aaron Thornton, W. Chad Henry and Chris Allison of GKN Aerospace. The research was funded 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 withGKNAerospace, under contract No. NFE-15-05725. 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. 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).
Keywords
- Interlayer cooling time
- Large-scale additivemanufacturing
- Part deformation
- Process parameter optimization
- Ti-6Al-4V