Abstract
Directed Energy Deposition (DED) Additive Manufacturing (AM) processes have a great potential to be used as cost-effective and efficient repairing and re-manufacturing processes for aerospace components such as turbine blades and landing gears. The AMOS project intends to connect repair and re-manufacturing strategies with design through accurate DED process simulation and novel multi-disciplinary design optimisation (MDO) methods. The ultimate goal is to reduce aerospace component weaknesses at design stage and prolong their lifecycles. DED AM processes are multi-physical phenomena involving high laser power melting powder or wire on a substrate. An experimental heat source has been calibrated using a heat transfer analysis of IN718 laser and powder AM on a sample part. Residual stresses and final distortion are also computed using thermal field and the evolving part distortion at each increment. Multiple hypotheses have been considered model the molten pool creation on the Heat Affected Zone (HAZ).
Highlights
Directed Energy Deposition (DED) Additive Manufacturing (AM) process simulation is extremely challenging
This paper proposes a thermomechanical approach using ABAQUS solver capabilities
Concerning heat source calibration, each layer deposition was simulated in a single pass
Summary
DED AM process simulation is extremely challenging. Multiple physical phenomena occur simultaneously such as fluid flow of blown powders, physics of heat generation due to laser beam, heat transfer into the AM part, and solid deformation. A molten pool called Heat Affected Zone (HAZ) is locally created. The global structure stiffness is modified due to residual stress introduction. Process-induced stresses and distortions can be anticipated by Finite Element Analysis predictions. An uncoupled heat transfer analysis which has been investigated is in reality a weak coupling thanks to the Element Progressive Activation method which accounts for geometrical non-linearity. A complete thermal calculation computes thermal field in the entire part for each time increment. Thermal field is mapped at each increment of a stress analysis to determine final distortions and residual stresses
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