Abstract
The Rapid Additive Forging (RAF) process is a Direct Energy Deposition (DED) Additive Manufacturing (AM) process, based on the deposition of a Titanium alloy on a substrate plate. This process has been developed for the production of Titanium parts of aeronautic components. In this study, a Finite Element (FE) numerical simulation methodology has been established to perform a fast analysis of the RAF process, including full 3D-transient thermal-metallurgical and mechanical numerical simulations. Thus, residual stresses and distortions caused by the process can be estimated. Different modelling strategies have been compared in order to find a balance between computation time and accuracy. Analyses include the effects of phase transformations in the Titanium alloy. First analyses have been performed on a simple geometry of welding wall. The influences of the material activation modelling strategy on the thermal and mechanical results have been investigated. The effects of phase transformations on residual stresses and distortions are also discussed. Then a specimen with a more complex geometry has been considered in the analysis, including the effect of different deposition paths. A full 3D simulation of the whole deposition process has been compared with several simplified computation procedures, including a reduction of the number of layers considered in the simulation.
Highlights
Additive Manufacturing (AM) by welding-like metal deposition process appears very attractive to manufacture pieces of large scale, especially for aircraft components
In order to produce Titanium parts for aeronautic components, a specific process, the Rapid Additive Forging (RAF) process has been developed by Prodways
Numerical simulation is an interesting alternative to experimental design campaigns, so as to understand the effects of weld parameters, clamping conditions, preheating, etc..., especially on residual stresses and distortions
Summary
Additive Manufacturing (AM) by welding-like metal deposition process appears very attractive to manufacture pieces of large scale, especially for aircraft components. In order to produce Titanium parts for aeronautic components, a specific process, the Rapid Additive Forging (RAF) process has been developed by Prodways. A modelling of the RAF process has been developed, in order to better understand the involved phenomena, and to investigate the effects of various parameters. With this model, various numerical simulations of metallic deposition have been performed, on different test-cases, in order to calibrate the simulation methodology. A more complex case has been considered (piece with H like geometry) for the simulation, considering different kinds of material (Nickel-based alloys or austenitic steels), so as to investigate the effects of path deposition and simplified simulation procedures. All the simulations are performed with the FE code Abaqus (Simulia)
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