Abstract
In this study, 3D printing of Ti6Al4V alloy is realized and the characteristics of the printed layer are examined. The morphological structures and metallurgical changes in the printed layer are assessed. Temperature and stress fields are simulated in line with the experimental conditions. Since the air gaps are present in between the loose alloy powders prior to the printing, the effective properties incorporating the air fraction are determined and the effective properties are used in the simulations. Thermal conductivity of the loose alloy powders with the presence of air gaps is determined by incorporating the virtual experimental technique. It is found that the printed layer is free from micro-cracks and large scale asperities; however, some small pores sites are observed because of the release of air around the loose powders during the printing. Microhardness of the printed surface is higher in the top surface of the printed layer than that of as-received solid alloy. In addition, the friction coefficient of the printed surface remains lower than that of the conventionally produced solid surface. The columnar structures are formed in the mid-section of the printed layer and slanted grains are developed in the region of the top and the bottom surface of the printed layer.
Highlights
Additive manufacturing becomes one of the important lines of production in various industries, and it remains critical for the efficient and fast production of the parts and the components. 3D printing plays a vital role in additive manufacturing among the other processes, such as stereolithography fused deposit modeling, laser selective melting and net shaping
3D printing is used for prototyping of the objects while creating the object replicate via forming sequential layers unlike material removal adopted in conventional machining processes
The high temperature gradients formed during processing causes high stress fields developed in the printed material, which may cause crack formation, or enables the printed layer being vulnerable to the mechanical failure under the fatigue loading
Summary
Additive manufacturing becomes one of the important lines of production in various industries, and it remains critical for the efficient and fast production of the parts and the components. 3D printing plays a vital role in additive manufacturing among the other processes, such as stereolithography fused deposit modeling, laser selective melting and net shaping. In thermal modeling of the high energy beam (3D) printing process, the distribution of the metallic powders and the air gaps in the printed region remain critical for the assessment of the appropriate thermal properties including the effective thermal conductivity and the specific heat. Thermal analysis of high-energy (3D) printing of a layer using the Ti6Al4V alloy powders is considered.
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