Abstract
Simulating the additive manufacturing process of Ti-6Al-4V is very complex due to the microstructural changes and allotropic transformation occurring during its thermomechanical processing. The -phase with a hexagonal close pack structure is present in three different forms—Widmanstatten, grain boundary and Martensite. A metallurgical model that computes the formation and dissolution of each of these phases was used here. Furthermore, a physically based flow-stress model coupled with the metallurgical model was applied in the simulation of an additive manufacturing case using the directed energy-deposition method. The result from the metallurgical model explicitly affects the mechanical properties in the flow-stress model. Validation of the thermal and mechanical model was performed by comparing the simulation results with measurements available in the literature, which showed good agreement.
Highlights
Powder Bed Fusion (PBF) is the technique of building thin layer over layer by melting the fine metal powder
The deposition path is generated from computer-aided design (CAD) geometry and is preprogrammed in a computer numerically controlled (CNC) machine, which makes the process very flexible and suitable for low volume production, eliminating the need for tooling and dies.This enables the production of complicated geometries that are traditionally difficult to produce with conventional manufacturing processes
One of the challenges involved in the additive manufacturing (AM) process is residual deformation and stresses due to the thermal dilatation of the substrate and added structure
Summary
Powder Bed Fusion (PBF) is the technique of building thin layer over layer by melting the fine metal powder. A few researchers have performed AM simulations or similar processes for Ti alloys using thermomechanical–microstructural (TMM) coupled material models. Materials 2019, 12, 3844 a thermomicrostructural model for Ti6Al-4V was presented and applied to a DED process. Presented a similar model and applied it on a PBF process, while Vastola et al [5] compared the results when modelling electron-beam melting (EBM) and PBF processes. Song et al [6] performed a welding simulation by using a TA15 alloy employing a TMM model. Cao et al [8] showed an AM simulation using electron-beam melting without including microstructural coupling. A TMM material model was employed by Ahn et al [9] for welding simulation ignoring strain-rate dependence. Murgau et al [12], which is included in the current special issue
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