Simulating the Geometric Distortion of Remanufactured Parts Using the Inherent Strain Method

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Directed energy deposition (DED) is an additive manufacturing technique that is very well adapted for remanufacturing metallic components. The process works by depositing material onto either a substrate or, in the case of remanufacturing, existing component using a metal wire or powder that is fed into an energy source, usually either a laser or electron beam. DED naturally introduces a large amount of heat into the component in a manner that generally produces both large and sharp temperature gradients. These gradients generate residual stresses in the material which cause the component to warp in ways that are often difficult to accurately predict. To use this method for remanufacturing components with specific geometrical demands, such as turbine blades, any potential warping must be accounted for and minimized. A simulation methodology based on inherent strain (IS) is proposed as a high-throughput high accuracy method of evaluating the warping based on the geometry and parameters of an individual component. The study compares the results of this high throughput IS-based simulation tool with more traditional thermomechanical simulations with respect to both accuracy and time efficiency when applied to an industrial case.