Optimized Inconel 718 pressure vessel manufactured with laser powder bed fusion

Abstract

Laser powder bed fusion (L-PBF) is one of the most novel additive manufacturing methods used for a wide range of industrial grade metallic materials. The process can produce end-use metal parts with desirable qualities and mechanical properties. L-PBF however, remains a complicated and expensive manufacturing method. Design for additive manufacturing (DfAM) is a key aspect leveraging the uptake of advantages and possibilities offered by AM in augmenting its competitiveness against conventional manufacturing (CM) methods. Inconel 718 (IN718) is a nickel-based superalloy boasting high temperature strength, good oxidation, and corrosion resistance at elevated temperatures. IN718 is commonly used for high performance applications, such as power and process industry parts, and gas turbine components. High inherent toughness, hardness, work hardening, and low thermal conductivity properties make the material difficult to manufacture through conventional machining methods. The layer-by-layer building of powder metals via L-PBF makes it possible to build different geometrical intricacy. The offered manufacturing flexibility for complex high-end metal structures for variety of applications makes L-PBF an alternative manufacturing method for high performance metals. This study investigates use of DfAM for a small-scale pressure vessel with predefined geometry, dimensions, design space and load condition. The aim is to introduce and exploit contemporary design optimization methods and their feasibility with AM. Structures, such as lattices and stress field driven geometries based on finite element analysis are investigated in this study. The designs are virtually tested under predefined pressure load of 50 bar. All four design options are manufactured on EOS M290 and IN718 powder. The result of the study shows the different optimizations decrease weight and improve material savings without compromising the linear load capacity. Optimized designs could also be made in such a way that it does not increase the manufacturing duration or add additional steps to it.