Abstract
This paper focuses on investigating the residual stress values associated with a part fabricated by Selective Laser Melting technology (SLM) when this is subjected further to forces on single point incremental forming (SPIF) operation of variable wall angle. The residual stresses induced by the SLM manufacturing process on the fabricated AlSi10Mg metallic sheets, as well as those produced during their forming SPIF operation were determined by X-ray diffraction (XRD) measurements. Significant residual stress levels of variation, positive or negative, along the metallic sample were observed because of the bending effects induced by the SPIF processes. It is also shown how the wall thickness varies along the additive manufactured SPIFed part as well as the morphology of the melting pools as a function of the deformation depth.
Highlights
Additive Manufacturing (AM) is a process of joining materials to produce components fromInstitute Laser Technology in the mid. 1990s
In order to study the evolution of the microstructure of AM metallic sheets and the impact that the single point incremental forming (SPIF) forming process has on the melt-pool morphology, SEM images were obtained along the cross sectional area of the formed aluminum samples
XDR measurements showed that AlSi10Mg metallic sheets produced by AM technology have only compressive residual stresses on the top and bottom sheet surfaces with a maximum average magnitude value of −92 MPa
Summary
Additive Manufacturing (AM) is a process of joining materials to produce components from. Extensive studies are required to evaluate the mechanical performance of the fabricated SLM parts before these are assembled into a final product One of these focuses on determining residual stress that are created when a part is processed by SLM technology because of the high temperature gradients, thermal expansion, and non-uniform plastic deformation during heating and cooling cycle. In order to reduce the undesirable residual stress effects that influence the part mechanical performance, post-processing operations such as shot-peening, grinding, heat treatment, age hardening, or polishing are used to treat the parts fabricated by SLM [15] These tend to improve the material ductility, increases the fracture toughness threshold value for crack initiation, and reduce surface roughness that affect fatigue performance [16]. We investigated potential effects such as different residual stress levels of variation, positive or negative, along the sample surfaces that were observed during experimental measurements because of the bending stresses induced by the SPIF processes
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