Thermomechanical Process Simulation and Experimental Verification for Laser Additive Manufacturing of Inconel®718
Linked Agent
Wang, Jinnan, Author
Zhang, Zhenlin , Author
Wu, Chaochao, Author
Zhao, Haiyan, Author
Hussain, Ghulam, Author
Ma, Ninshu , Author
Title of Periodical
Materials
Issue published
Volume 16 - Issue 7
Country of Publication
Switzerland
Place Published
Basel, Switzerland
Publisher
MDPI
Date Issued
2023
Language
English
Subject
English Abstract
Abstract:
Laser cladding has emerged as a promising technique for custom-built fabrications, remanufacturing, and repair of metallic components. However, frequent melting and solidification in the process cause inevitable residual stresses that often lead to geometric discrepancies and deterioration of the end product. The accurate physical interpretation of the powder consolidation process remains challenging. Thermomechanical process simulation has the potential to comprehend the layer-by-layer additive process and subsequent part-scale implications. Nevertheless, computational accuracy and efficacy have been serious concerns so far; therefore, a hybrid FEM scheme is adopted for efficient prediction of the temperature field, residual stress, and distortion in multilayer powder-fed laser cladding of Inconel®718. A transient material deposition with powder material modeling is schematized to replicate the fabrication process. Moreover, simulation results for residual stress and distortion are verified with in-house experiments, where residual stress is measured with XRD (X-Ray Diffraction) and geometric distortion is evaluated with CMM (Coordinate Measuring Machine). A maximum tensile residual stress of 373 ± 5 MPa is found in the vicinity of the layer right in the middle of the substrate and predicted results are precisely validated with experiments. Similarly, a 0.68 ± 0.01 mm distortion is observed with numerical simulation and showed a precise agreement with experimental data for the same geometry and processing conditions. Conclusively, the implemented hybrid FEM approach demonstrated a robust and accurate prediction of transient temperature field, residual stresses, and geometric distortion in the multilayer laser cladding of Inconel®718.
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Identifier
https://digitalrepository.uob.edu.bh/id/30441035-82fd-4387-b54a-15e50f1a37a4
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