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X-ray diffraction measurements and computational prediction of residual stress mitigation scanning strategies in powder bed fusion additive manufacturing

DOI: 10.1016/j.addma.2022.103275 DOI Help

Authors: Wenyou Zhang (University of Galway) , Da Guo (University of Manchester) , Lin Wang (Nanjing University of Aeronautics and Astronautics) , Catrin M. Davies (Imperial College London) , Wajira Mirihanage (University of Manchester) , Mingming Tong (University of Galway; I-Form, the SFI Research Centre for Advanced Manufacturing) , Noel M. Harrison (University of Galway; I-Form, the SFI Research Centre for Advanced Manufacturing)
Co-authored by industrial partner: No

Type: Journal Paper
Journal: Additive Manufacturing , VOL 29

State: Published (Approved)
Published: November 2022
Diamond Proposal Number(s): 21946

Abstract: The repeated localised heating-melting-cooling-solidification processes during laser beam powder bed fusion (PBF-LB) additive manufacturing (AM) induce intricate thermal residual stress (RS) in manufactured parts. Non-destructive characterisation using X-ray diffraction was used to measure the RS of Ti-6Al-4V square plates that were manufactured by using six different scanning strategies. Computational modelling was used to interpret the experimental stress measurement results. It was revealed that an inclined scanning strategy is beneficial for reducing the average through-thickness RS because the inclined scanning strategy can mitigate the non-uniform thermal profile and corresponding residual thermal stresses in successive layers of material. Among all the different scanning strategies that were analysed in this work, the 45° inclined 90° rotation scanning resulted in the lowest RS. The thicker parts have a greater gradient of RS than the thinner parts, after base plate removal. This research outcome can help the AM industry to design or optimise the process parameters of the PBF-LB aiming to minimise the RS of metal parts.

Journal Keywords: Powder bed fusion; Additive manufacturing; Residual stress; High energy X-ray diffraction; Scanning strategy

Diamond Keywords: Additive Manufacturing

Subject Areas: Materials, Engineering

Instruments: I12-JEEP: Joint Engineering, Environmental and Processing

Added On: 16/11/2022 11:16

Discipline Tags:

Materials Engineering & Processes Materials Science Engineering & Technology

Technical Tags: