Effect of Inter-Layer Dwell Time on Distortion and Residual Stresses of Laser Metal Deposited Wall

Abstract:

The laser metal deposition is an advanced manufacturing technology enabling the production of large-sized parts and partially or completely elimination of machining and welding. The process is characterised by a non-uniform local heating of the buildup leading to a stress distribution, which may exceed the yield strength of the material and leads to loss of dimensional accuracy. The interlayer dwell time has a strong influence on the temperature field. The effect of the interlayer dwell time on the distortion and the stress distribution during laser metal deposition of a single-pass wall on the edge of 2 mm thick plate was studied experimentally and numerically. The deposited material was IN625 and the substrate material was AISI 316. A decrease of the residual displacement, due to a uniform shrinkage after the deposition of the last layer and a lower level of the residual compressive longitudinal plastic strain, has been observed in the studies without a dwell time. The peak increment of the free edge displacement corresponds to the first layer and hence the subsequent layers will be deposited on the already plastically deformed buildup. The tensile residual longitudinal stress near the top of the buildup and transverse stress near the edges of the buildup is higher than yield strength in the studies with dwell time.

• Periodical: Key Engineering Materials (Volume 822)
• Pages: 445-451
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.822.445
• Online since: September 2019
• Authors: Sergei Yu. Ivanov*, Artur Vildanov, Pavel A. Golovin, Antoni Artinov, Ivan Karpov
• Keywords: Distortion, Laser Metal Deposition, Residual Stresses, Simulation, Temperature Field

References

[1] L.A. Magerramova, G.A. Turichin, Y.A. Nozhnitsky, O.G. Klimova-Korsmik, B.E. Vasiliev, M.E. Volkov, A.V. Salnikov, Peculiarities of additive technologies application in the production of gas turbine engine parts, Journal of Physics: Conference Series, 1109 (1) (2018) 012051.

DOI: 10.1088/1742-6596/1109/1/012051

[2] R.V. Mendagaliyev, O.G. Klimova-Korsmik, K.M. Medvedeva, A.A. Voropayev, A.D. Eremeev, I.A. Tsibulsky, E.A. Norman, Features of structure formation and properties at laser and arc surfacing from steel wire, Journal of Physics: Conference Series (2018), 1109 (1), 012040.

DOI: 10.1088/1742-6596/1109/1/012040

[3] S.A. Shalnova, O.G. Klimova-Korsmik, M.O. Sklyar, Influence of the roughness on the mechanical properties of ti-6al-4v products prepared by direct laser deposition technology, Solid State Phenomena 284 (2018), 312-318.

DOI: 10.4028/www.scientific.net/ssp.284.312

[4] V. Glukhov, G. Turichin, O. Klimova-Korsmik, Quality management of metal products prepared by high-speed direct laser deposition technology, Key Engineering Materials 684 (2016) 461-467.

DOI: 10.4028/www.scientific.net/kem.684.461

[5] M.O. Sklyar, O.G. Klimova-Korsmik, V.V. Cheverikin, Formation structure and properties of parts from titanium alloys produced by direct laser deposition, Solid State Phenomena 265 (2017), 535-541.

DOI: 10.4028/www.scientific.net/ssp.265.535

[6] I.A. Tsibulskiy, V.V. Somonov, R.S. Korsmik, M.O. Gushchina, A.D. Eremeev, The influence of technological parameters on the structure formation of aluminum alloys during direct deposition of wire, Journal of Physics: Conference Series (2018), 1109 (1), 012032.

DOI: 10.1088/1742-6596/1109/1/012032

[7] M. Biegler, A. Marko, B. Graf, M. Rethmeier, Finite element analysis of in-situ distortion and bulging for an arbitrarily curved additive manufacturing directed energy deposition geometry, Additive Manufacturing, 24 (2018) 264-272.

DOI: 10.1016/j.addma.2018.10.006

[8] M. Gouge, P. Michaleris, Thermo-Mechanical Modeling of Additive Manufacturing, first ed., Butterworth-Heinemann, (2017).

[9] G. Turichin, E. Zemlyakov, K. Babkin, S. Ivanov, A. Vildanov, Analysis of distortion during laser metal deposition of large parts, Procedia CIRP, 74 (2018) 154-157.

DOI: 10.1016/j.procir.2018.08.068

[10] P.A. Golovin, A.M. Vildanov, K.D. Babkin, S.Y. Ivanov, I.K. Topalov, Distortion prevention of axisymmetric parts during laser metal deposition Journal of Physics: Conference Series, 1109 (1) (2018) 012065.

DOI: 10.1088/1742-6596/1109/1/012065

[11] T. Mukherjee, W. Zhang, T. DebRoy, An improved prediction of residual stresses and distortion in additive manufacturing, Computational Materials Science, 126 (2017) 360-372.

DOI: 10.1016/j.commatsci.2016.10.003

[12] V.T. Em, S.Y. Ivanov, I.D. Karpov, S.A. Rylov, E.V. Zemlyakov, K.D. Babkin, Residual stress measurements of laser metal deposited Ti-6Al-4V parts using neutron diffraction, Journal of Physics: Conference Series, 1109 (1) (2018) 012049.

DOI: 10.1088/1742-6596/1109/1/012049

[13] Z. Wang, E. Denlinger, P. Michaleris, A.D. Stoica, D. Ma, M. Beese, Residual stress mapping in Inconel 625 fabricated through additive manufacturing: Method for neutron diffraction measurements to validate thermomechanical model predictions, Materials & Design, 113 (2017) 169-177.

DOI: 10.1016/j.matdes.2016.10.003

[14] F. Bayerlein, F. Bodensteiner, C. Zeller, M. Hofmann, M.F. Zaeh, Transient development of residual stresses in laser beam melting – A neutron diffraction study, Additive Manufacturing, 24 (2018) 587-594.

DOI: 10.1016/j.addma.2018.10.024

[15] T. Debroy, H. L. Wei, J. S. Zuback, T. Mukherjee, J. W. Elmer, J. O. Milewski, Allison Michelle Beese, A. Wilson-Heid, A. De, W. Zhang, Additive manufacturing of metallic components – process, structure and properties, Progress in Materials Science, 92 (2018) 112-224.

DOI: 10.1016/j.pmatsci.2017.10.001

[16] D.D. Gu, W. Meiners, K. Wissenbach, R. Poprawe, Laser additive manufacturing of metallic components: materials, processes and mechanisms, International materials reviews 57, 3 (2012) 133-164.

DOI: 10.1179/1743280411y.0000000014

[17] Y. Ueda, Welding Deformation and Residual Stress Prevention, first ed., Butterworth-Heinemann, (2012).

[18] L.E. Lindgren, Computational Welding Mechanics, first ed., Woodhead Publishing, (2007).

[19] K.C. Mills, Recommended Values of Thermophysical Properties for Selected Commercial Alloys, Woodhead Publishing, Cambridge, (2002).

[20] Nickel Development Institute, High-temperature high strength nickel base alloys, Nickel Development Institute, 393 (1995).