Abstract
Simulations of laser-based directed energy deposition of metals have received increasing interest aimed at reducing the experimental effort to select the proper processing condition for the repair or overhaul of actual components. One of the main issues to be addressed is the evaluation of the residual stress, which may lead to part failure under nominal loading. In this frame and specifically relating to aluminum alloys, few works have been developed and validated. This lack of knowledge is addressed in this paper: namely, the proper approach to simulate the activation of the deposited metal is discussed in case of single deposition and is shifted to a case of multiple depositions over a substrate. The validation of the predicted residual stress is made by comparison with the actual stress resulting from X-ray diffraction.
Highlights
The process of directed energy deposition (DED) of metals, in the family of additive manufacturing technologies, isInt J Adv Manuf Technol increasingly used thanks to its flexibility in terms of base material [1]
It has been already shown that untreated residual stress may induce fracture under loading and reduce the fatigue life and the mechanical properties of the repaired or coated part [10, 11]; proper heat treating can be performed to release the stresses depending on the metal alloy [12, 13], deformations arising during the process may result in a mismatch with respect to the intended geometry and even compromise the product integrity [7, 10] or the repair quality in general [3]
This paper presented a finite element modelling technique to predict the residual stress state induced by directed energy deposition on a workpiece
Summary
The process of directed energy deposition (DED) of metals, in the family of additive manufacturing technologies, is. A significant effort is devoted at present to implement reliable simulations, allowing to predict of multiple responses including the residual stress and the final geometry, the thermal field and the deformations, based on the levels of the governing factors. With this approach, the need for an expensive and timeconsuming experimental campaign would be significantly reduced. In the frame of modelling the process of DED of aluminum alloys, this paper is focused on presenting a structured approach to predict the residual stress, considering the governing factors and the geometry of the deposited metal (Fig. 1). The predicted residual stress has been validated by comparison with the actual stress resulting from X-ray diffraction
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