Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire

Yousub Lee,Brian T Gibson,Brad Richardson,Peeyush Nandwana,Yashwanth Bandari,Srdjan Simunovic

doi:10.3390/app9235115

Yousub Lee, Brian T Gibson + Show 4 more

Open Access

https://doi.org/10.3390/app9235115

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Abstract

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency 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.

Highlights

In the past decade, metal additive manufacturing (AM) has evolved from rapid prototyping and low volume production to mass production of various metallic components [1]
The laser metal deposition with wire (LMD-w) system consists of a laser heat source mounted on a robotic arm, a wire feeder, tables, and tools for process conditions
Six walls were built with different interlayer cooling times, and the effect on part distortion is shown in were

Summary

Introduction

Metal additive manufacturing (AM) has evolved from rapid prototyping and low volume production to mass production of various metallic components [1]. This trend has triggered a need for manufacturing processes that have high deposition rates, such as metal big area. AM (mBAAM) or laser metal deposition with wire (LMD-w) AM [1,2,3,4,5]. The laser metal deposition with wire (LMD-w) system consists of a laser heat source mounted on a robotic arm, a wire feeder, tables, and tools for process conditions (e.g., cameras and thermocouples). As a result of this layer-by-layer deposition, every deposited layer except for the last one undergoes multiple heating and cooling cycles, which typically produces non-uniform thermal stress and distortion in the final parts [6]

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