A V Model Framework To Support Qualification Of Metal Additive Manufacturing Parts Made With Laser Powder Bed Fusion

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A V-Model Framework to Support Qualification of Metal Additive Manufacturing Parts Made with Laser Powder Bed Fusion

Author : Byeong Min Roh
Publisher :
ISBN 13 :
Total Pages : 0 pages
Book Rating : 4.:/5 (136 download)

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Book Synopsis A V-Model Framework to Support Qualification of Metal Additive Manufacturing Parts Made with Laser Powder Bed Fusion by : Byeong Min Roh

Download or read book A V-Model Framework to Support Qualification of Metal Additive Manufacturing Parts Made with Laser Powder Bed Fusion written by Byeong Min Roh and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: This dissertation presents a novel framework for monitoring metal additive manufacturing (AM) processes for quality assurance using process signatures occurring during the laser powder bed fusion process. The framework offers a structured approach based on the Systems Engineering V-model to translate part requirements into process signatures that can be monitored using in situ sensing technologies. A method for selecting sensors based on the process signatures of interest is also developed to address a related shortcoming in the field. Information gathered from the selected sensors during the build is used to ascertain build quality with respect to the microstructure and mechanical properties of the resulting metal AM part. This information can then be used for quality assurance, validating that the requirements are met by the metal AM part. The V-model framework and sensor selection method for laser powder bed fusion are demonstrated and tested using existing Ti-6Al-4V and IN625 test data from the literature to validate traceability and requirements for density and ultimate tensile strength. The contributions of the work are discussed in this dissertation, along with limitations and future work.

Data-Driven Modeling for Additive Manufacturing of Metals

Author : National Academies of Sciences, Engineering, and Medicine
Publisher : National Academies Press
ISBN 13 : 0309494230
Total Pages : 79 pages
Book Rating : 4.3/5 (94 download)

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Book Synopsis Data-Driven Modeling for Additive Manufacturing of Metals by : National Academies of Sciences, Engineering, and Medicine

Download or read book Data-Driven Modeling for Additive Manufacturing of Metals written by National Academies of Sciences, Engineering, and Medicine and published by National Academies Press. This book was released on 2019-10-09 with total page 79 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) is the process in which a three-dimensional object is built by adding subsequent layers of materials. AM enables novel material compositions and shapes, often without the need for specialized tooling. This technology has the potential to revolutionize how mechanical parts are created, tested, and certified. However, successful real-time AM design requires the integration of complex systems and often necessitates expertise across domains. Simulation-based design approaches, such as those applied in engineering product design and material design, have the potential to improve AM predictive modeling capabilities, particularly when combined with existing knowledge of the underlying mechanics. These predictive models have the potential to reduce the cost of and time for concept-to-final-product development and can be used to supplement experimental tests. The National Academies convened a workshop on October 24-26, 2018 to discuss the frontiers of mechanistic data-driven modeling for AM of metals. Topics of discussion included measuring and modeling process monitoring and control, developing models to represent microstructure evolution, alloy design, and part suitability, modeling phases of process and machine design, and accelerating product and process qualification and certification. These topics then led to the assessment of short-, immediate-, and long-term challenges in AM. This publication summarizes the presentations and discussions from the workshop.

Laser-Based Additive Manufacturing of Metal Parts

Author : Linkan Bian
Publisher : CRC Press
ISBN 13 : 1351647482
Total Pages : 422 pages
Book Rating : 4.3/5 (516 download)

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Book Synopsis Laser-Based Additive Manufacturing of Metal Parts by : Linkan Bian

Download or read book Laser-Based Additive Manufacturing of Metal Parts written by Linkan Bian and published by CRC Press. This book was released on 2017-08-09 with total page 422 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser-Based Additive Manufacturing (LBAM) technologies, hailed by some as the "third industrial revolution," can increase product performance, while reducing time-to-market and manufacturing costs. This book is a comprehensive look at new technologies in LBAM of metal parts, covering topics such as mechanical properties, microstructural features, thermal behavior and solidification, process parameters, optimization and control, uncertainty quantification, and more. The book is aimed at addressing the needs of a diverse cross-section of engineers and professionals.

Support Structure Design in Additive Manufacturing

Author : Sebastian Weber
Publisher :
ISBN 13 : 9783844089257
Total Pages : 0 pages
Book Rating : 4.0/5 (892 download)

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Book Synopsis Support Structure Design in Additive Manufacturing by : Sebastian Weber

Download or read book Support Structure Design in Additive Manufacturing written by Sebastian Weber and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Laser Powder Bed Fusion Process

Author : AMS AM Additive Manufacturing Metals
Publisher :
ISBN 13 :
Total Pages : 0 pages
Book Rating : 4.:/5 (137 download)

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Book Synopsis Laser Powder Bed Fusion Process by : AMS AM Additive Manufacturing Metals

Download or read book Laser Powder Bed Fusion Process written by AMS AM Additive Manufacturing Metals and published by . This book was released on 2018 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: This specification establishes process controls for the repeatable production of aerospace parts by Laser Powder Bed Fusion (L-PBF). It is intended to be used for aerospace parts manufactured using Additive Manufacturing (AM) metal alloys, but usage is not limited to such applications. The manufacturing process is unique relative to traditional or 'subtractive' methods and this documents is intended to provide technical information on laser powder bed process specifications, NDI methods, and generally accepted best practices to produce parts capable of service in critical and non-critical aerospace service. No such document currently exists.

Fundamentals of Laser Powder Bed Fusion of Metals

Author : Igor Yadroitsev
Publisher : Elsevier
ISBN 13 : 0128240911
Total Pages : 678 pages
Book Rating : 4.1/5 (282 download)

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Book Synopsis Fundamentals of Laser Powder Bed Fusion of Metals by : Igor Yadroitsev

Download or read book Fundamentals of Laser Powder Bed Fusion of Metals written by Igor Yadroitsev and published by Elsevier. This book was released on 2021-05-23 with total page 678 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser powder bed fusion of metals is a technology that makes use of a laser beam to selectively melt metal powder layer-by-layer in order to fabricate complex geometries in high performance materials. The technology is currently transforming aerospace and biomedical manufacturing and its adoption is widening into other industries as well, including automotive, energy, and traditional manufacturing. With an increase in design freedom brought to bear by additive manufacturing, new opportunities are emerging for designs not possible previously and in material systems that now provide sufficient performance to be qualified in end-use mission-critical applications. After decades of research and development, laser powder bed fusion is now enabling a new era of digitally driven manufacturing. Fundamentals of Laser Powder Bed Fusion of Metals will provide the fundamental principles in a broad range of topics relating to metal laser powder bed fusion. The target audience includes new users, focusing on graduate and undergraduate students; however, this book can also serve as a reference for experienced users as well, including senior researchers and engineers in industry. The current best practices are discussed in detail, as well as the limitations, challenges, and potential research and commercial opportunities moving forward. Presents laser powder bed fusion fundamentals, as well as their inherent challenges Provides an up-to-date summary of this advancing technology and its potential Provides a comprehensive textbook for universities, as well as a reference for industry Acts as quick-reference guide

Multiscale Modeling of Additively Manufactured Metals

Author : Yi Zhang
Publisher : Elsevier
ISBN 13 : 0128225599
Total Pages : 252 pages
Book Rating : 4.1/5 (282 download)

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Book Synopsis Multiscale Modeling of Additively Manufactured Metals by : Yi Zhang

Download or read book Multiscale Modeling of Additively Manufactured Metals written by Yi Zhang and published by Elsevier. This book was released on 2020-06-29 with total page 252 pages. Available in PDF, EPUB and Kindle. Book excerpt: Multiscale Modeling of Additively Manufactured Metals: Application to Laser Powder Bed Fusion Process provides comprehensive coverage on the latest methodology in additive manufacturing (AM) modeling and simulation. Although there are extensive advances within the AM field, challenges to predictive theoretical and computational approaches still hinder the widespread adoption of AM. The book reviews metal additive materials and processes and discusses multiscale/multiphysics modeling strategies. In addition, coverage of modeling and simulation of AM process in order to understand the process-structure-property relationship is reviewed, along with the modeling of morphology evolution, phase transformation, and defect formation in AM parts. Residual stress, distortion, plasticity/damage in AM parts are also considered, with scales associated with the spatial, temporal and/or material domains reviewed. This book is useful for graduate students, engineers and professionals working on AM materials, equipment, process, development and modeling. Includes the fundamental principles of additive manufacturing modeling techniques Presents various modeling tools/software for AM modeling Discusses various design methods and how to optimize the AM process using these models

Cost Modeling and Design Tools for Additive Manufacturing with Laser Powder Bed Fusion

Author : Michael W Barclift
Publisher :
ISBN 13 :
Total Pages : pages
Book Rating : 4.:/5 (18 download)

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Book Synopsis Cost Modeling and Design Tools for Additive Manufacturing with Laser Powder Bed Fusion by : Michael W Barclift

Download or read book Cost Modeling and Design Tools for Additive Manufacturing with Laser Powder Bed Fusion written by Michael W Barclift and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing (AM) is a novel process that uses 3D model data to create complex geometry and functional structures by joining materials layer-by-layer. Despite growing interest, industrys adoption of AM has been limited due to challenges in cost-effectiveness, lack of subject matter expertise, and disparities amongst commercial software programs that capture the full breadth of design inputs and process considerations for AM. Designers have limited tools within the 3D modeling (e.g., CAD) environment that inform them on critical design parameters and tradeoffs that can impact the overall cost and feasibility of producing a part in AM.In this thesis, cost modeling and design tools are examined for Laser-Powder Bed Fusion (LPBF). Traditional cost models have estimated that the material cost can range up to 46% of the total cost; however, these models have not accounted for the reuse (i.e., recycling) of the un-melted powder feedstock in LPBF. To capture susceptibilities to chemical contamination, diminished powder size distributions, and inconsistent mechanical performance, financial depreciation models using Sum-of-the-Years digits and Straight Line are implemented to define the value of a powder feedstock as function of each build cycle reuse in LPBF. A case-study is presented for an automotive upright designed for production and analyzed using a generic LPBF activity-based cost model. Sensitivity analysis revealed that traditional cost models assuming infinite material reuse undervalued the cost of build jobs with virgin powder by 3-11% or 13-75% depending on the material, feedstock price, and maximum permitted reuses in LPBF.Cost modeling is iterative and estimates will vary as updates are made to the 3D model. To aid in informing designers on costs of their parts, a software plug-in is presented using the SolidWorks Application Programming Interface (API) that integrates the proposed LPBF cost model within the 3D CAD environment. The tool enables designers to generate support structures and distinguish from internal and external supports on their part. In addition to querying volume and surface data from the 3D model, the manipulation of the parts build orientation allows designers to concurrently estimate build time, feedstock requirements, and optimize parts for AM production while they are being designed in CAD. A case study is presented for an automotive upright where results found that varying the support angle by 15 degrees, underpredicted support structure volume by 34% and build time by 20%. Furthermore, poor packing of geometries on the build platform led to powder depreciation costs being nearly twice the material costs. Based on this two-part study, recommendations are made for additional research on LPBF cost modeling, post-processing cost modeling, powder feedstock reusability metrics, and CAD-integrated design tools with greater inputs, support structure libraries, and considerations for AM processes.

Coupled Topology Optimization and Process Simulation System for Laser Powder-bed Fusion Additive Manufacturing

Author : Zhidong Zhang
Publisher :
ISBN 13 :
Total Pages : pages
Book Rating : 4.:/5 (126 download)

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Book Synopsis Coupled Topology Optimization and Process Simulation System for Laser Powder-bed Fusion Additive Manufacturing by : Zhidong Zhang

Download or read book Coupled Topology Optimization and Process Simulation System for Laser Powder-bed Fusion Additive Manufacturing written by Zhidong Zhang and published by . This book was released on 2019 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing (AM), widely known as 3D printing, is a transformative method to industrial manufacturing, helping in creating lighter, stronger, smarter parts and systems. As one of the most important and commercially available AM processes, Laser Powder-bed Fusion (LPBF) can realize geometrically complex metallic parts by selectively melting layers of metallic powders. It is being used extensively in many fields, such as medical, aeronautical, etc.. As AM provides new design opportunities, topology optimization is ideal for AM, specifically LPBF, because it can be deployed to design high-performance structures and fully exploit the fabrication freedom provided by AM. However, there are still some challenges of printing parts in LPBF, such as porosity creation, low surface quality, residual stress, and deformation, which impede its widespread use in industrial applications. These challenges can be controlled by better understanding the influence of the process parameters used in the LPBF process. Nevertheless, relying exclusively on experimental efforts is expensive and time-consuming. Therefore, the LPBF process modeling can help in understanding the effects of the process parameters on the printed part quality. Furthermore, LPBF modeling can be coupled with topology optimization to produce parts with lower as-built deformation. In this work, a coupled topology optimization and process simulation system is proposed to deal with the challenges and utilize the opportunities of the LPBF process. This system involves two major aspects: Firstly, a 3-dimensional heat transfer model is developed to study the effect of process parameters on printed LPBF parts. The simulation results show good agreement with experimental measurements. The averaged error of melt pool width and depth are 2.9% and 7.3%, respectively. Secondly, an Inherent Strain Method (ISM)-based topology optimization model is proposed to reduce the deformation in LPBF parts. A parallel-computing framework of this model is used to optimize the support structures to reduce the as-built and after-cut deflections of printed parts. Experimental results show the framework can reduce the part deformation of over 60% and also material usage of over 50% compared to commercial support structures. Besides, the ISM model has also been employed in predicting the deflections of printed parts, and when compared to experimental results, excellent agreement is observed (average 6% error). Lastly, the parallel-computing framework can achieve considerable simulation acceleration.

A Framework to Develop Processing-microstructure-mechanical Behavior Relationships for Metal Additive Manufacturing

Author : Emine Tekerek
Publisher :
ISBN 13 :
Total Pages : 0 pages
Book Rating : 4.:/5 (139 download)

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Book Synopsis A Framework to Develop Processing-microstructure-mechanical Behavior Relationships for Metal Additive Manufacturing by : Emine Tekerek

Download or read book A Framework to Develop Processing-microstructure-mechanical Behavior Relationships for Metal Additive Manufacturing written by Emine Tekerek and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser powder bed fusion (L-PBF) is a promising Metal Additive Manufacturing (MAM) method which offers design flexibility in producing geometrically complex metallic parts in a short production time. During the LPBF process, the input material undergoes multi-physics nature and thermal cycles related to the laser-induced, layer-by-layer solidification and melting of the powder feed-stock material. This process leads to different microstructural evolutions and results to both material and geometrical defects in the as-manufactured state, as well as to uncertainty in the overall mechanical behavior of L-PBF produced as-build parts compared to the traditionally manufactured ones. Therefore, this dissertation focuses on damage mechanisms of L-PBF produced as-build AlSi10Mg alloys under monotonic tension and cyclic loading. Most emphasis in the literature has been given either the effects of defects on the mechanical properties of this material or fracture for performance considerations. In this dissertation, a technical workflow which leverages a critical combination of tools and methods, is presented which together investigate ways to both define and also reduce the parametric space which affects the quality of as-built AlSi10Mg alloys by implementing on axis, melt-pool scale, in situ monitoring data collected during the AM process were examined in conjunction with the formation of flaws. The research plan prioritizes on developing a design-of-experiments (DOE) approach capable of selecting the most important geometry, manufacturing, and material factors which could be varied parametrically to investigate the physical mechanisms involved in the solidification process in terms of crystallographic texture, grain size and sub-grain dislocation structures, phase transformations, secondary phase and precipitation formations and their role in fatigue of AM metals. Furthermore, the emphasis is placed on using nondestructive evaluation (NDE) combined with mechanical testing and characterization methods applied at a scale where damage incubation and initiation is occurring for this newly discovered microstructure. Specifically, a setup built inside a Scanning Electron Microscope (SEM) and retrofitted to be combined with characterization and NDE capabilities was developed with the goal to track the early stages of the damage incubation and microstructure-scale early crack initiation in this type of material. The characterization capabilities include Electron Backscatter Diffraction (EBSD) and Energy Dispersive Spectroscopy (EDS) in addition to X-ray micro-computed tomography ([mu]-CT) and nanoindentation, in addition to microscopy achieved by the Secondary Electron (SE) and Back Scatter Electron (BSE) detectors. Moreover, on axis, melt-pool scale, in situ monitoring data collected during the AM process were examined in conjunction with the formation of flaws. Extensions of the presented approach to include information from computational methods as well as their applicability to other material systems are discussed.

Process Design in Laser Powder Bed Fusion

Author : Seyyed Behzad Hosseini Rankouhi
Publisher :
ISBN 13 :
Total Pages : 0 pages
Book Rating : 4.:/5 (129 download)

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Book Synopsis Process Design in Laser Powder Bed Fusion by : Seyyed Behzad Hosseini Rankouhi

Download or read book Process Design in Laser Powder Bed Fusion written by Seyyed Behzad Hosseini Rankouhi and published by . This book was released on 2021 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) has brought about a new age of design and manufacturing where traditional constraints are eased or in some areas completely lifted. The integration of topology optimization (TO) and AM has the potential to revolutionize modern design and manufacturing. However, few instances of manufactured optimized designs are documented, and even fewer examples of experimentally tested designs are available. The lack of validation combined with the influence of AM process on material properties leaves a gap in our understanding of process-microstructure-property relationships that is essential for developing holistic design optimization frameworks. In the first chapter of this thesis, a functional design was topologically optimized and fabricated using both directed energy deposition (DED) and selective laser melting (SLM), also known as powder bed fusion (PBF), methods. It is shown that TO results are sensitive to the AM method, post-processing conditions, and differences in mechanical properties. Thus, a TO for AM framework can be best optimized with the incorporation of microstructure features to account for localized microstructural variations in fabricated components. One of the main challenges facing SLM process is finding suitable process parameters to achieve maximum density (pore-free) parts. In chapter two, two newly discovered dimensionless numbers are presented that correlate process parameters to a part's density allowing for an initial estimation of suitable process parameters without the need for extensive modeling or experimentation. The dimensionless numbers allow for identification of process parameters that will result in a maximum density regime in the as-built part. Finally, a universal scaling law is introduced that can aid in quantitative prediction of process parameters that result in the highest as-built density. Multi-material additive manufacturing using PBF has the potential to revolutionize the manufacturing landscape by producing parts with improved thermophysical properties and enhanced functionality. However, the complex nature of the process requires a case-by-case approach to multi-material characterization. The aim of chapter three is to provide firsthand knowledge of 316L stainless steel (316L) and Hastelloy X (HX) multi-material processing via PBF. Results showed that using the proper process parameters for each individual material led to formation of a compositional gradient at the interface that stretched for 240 ℗æm (10-12 layers) with no evidence of cracking or porosity. Finally, it was concluded that the "naturally" formed interface created a compositional gradient which was defect free due to similar values of coefficient of thermal expansion, energy density, dimensionless number Î 2, and different Marangoni numbers of the materials. The aim of chapter four is to propose a methodology for rapidly predicting suitable process parameters for additive manufacturing of multi-material parts with a compositional gradient by using machine learning and 316L-Cu bi-metal system. Specifically, an algorithm based on a multivariate Gaussian process is developed to predict part density and surface roughness for a given set of laser power, velocity, and hatch spacing values. After the model is validated using leave-one-out cross validation method, process parameter maps are generated for 316L-Cu parts manufactured using selective laser melting with premixed powder at mass fractions of 0.25, 0.50, and 0.75. It is shown that process parameters are a nonlinear function of gradient composition and neither process parameters of 316L or Cu are suitable for the graded region of a 316L-Cu multi-material part. Generated process maps provide a firsthand knowledge of process-property relationships for regions of compositional grading in 316L-Cu parts.

Laser-Based Additive Manufacturing

Author : Narendra B. Dahotre
Publisher : John Wiley & Sons
ISBN 13 : 3527347917
Total Pages : 308 pages
Book Rating : 4.5/5 (273 download)

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Book Synopsis Laser-Based Additive Manufacturing by : Narendra B. Dahotre

Download or read book Laser-Based Additive Manufacturing written by Narendra B. Dahotre and published by John Wiley & Sons. This book was released on 2022-08-01 with total page 308 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser-Based Additive Manufacturing Explore laser-based additive manufacturing processes via multi-scale modeling and computer simulation In Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments, a distinguished team of researchers delivers an incisive framework for understanding materials processing using laser-based additive manufacturing (LAM). The book describes the use of computational modeling and simulation to explore and describe the LAM technique, to improve the compositional, phase, and microstructural evolution of the material, and to enhance the mechanical, chemical, and functional properties of the manufactured components. The accomplished authors combine a comprehensive overview of multi-scale modeling and simulation with experimental and practical observations, offering a systematic review of laser-material interactions in advanced LAM processes. They also describe the real-world applications of LAM, including component processing and surface functionalization. In addition to explorations of residual stresses, three-dimensional defects, and surface physical texture in LAM, readers will also find: A thorough introduction to additive manufacturing (AM), including the advantages of AM over conventional manufacturing and the challenges involved with using the technology A comprehensive exploration of computation materials science, including length- and time-scales in materials modeling and the current state of computational modeling in LAM Practical discussions of laser-material interaction in LAM, including the conversion of light energy to heat, modes of heat dissipation, and the dynamics of the melt-pool In-depth examinations of the microstructural and mechanical aspects of LAM integrated with modeling Perfect for materials scientists, mechanical engineers, and physicists, Laser-Based Additive Manufacturing: Modeling, Simulation, and Experiments is perfect for anyone seeking an insightful treatment of this cutting-edge technology in the areas of alloys, ceramics, and composites.

Physics-based Surrogate Modeling of Laser Powder Bed Fusion Additive Manufacturing

Author : Alexander James Wolfer
Publisher :
ISBN 13 :
Total Pages : 0 pages
Book Rating : 4.5/5 (825 download)

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Book Synopsis Physics-based Surrogate Modeling of Laser Powder Bed Fusion Additive Manufacturing by : Alexander James Wolfer

Download or read book Physics-based Surrogate Modeling of Laser Powder Bed Fusion Additive Manufacturing written by Alexander James Wolfer and published by . This book was released on 2020 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) employs a layer-by-layer deposition process to enable the fabrication of parts that are challenging or impossible to prepare by traditional subtractive manufacturing methods. Metal-based AM processes, like laser powder bed fusion (L-PBF), have moved from a focus on prototypes and production of non-critical parts to a focus on production of mission-critical parts for use in biomedical or aerospace applications. As a result, there needs to be assurance that the parts manufactured using this technology are of the same quality every time they are produced. Exploring all possible parameter combinations experimentally, using trial-and-error methods, is tedious and costly. Due to the computational requirements of modeling this complex process, the most accurate high-fidelity simulations are not suitable for applications like process optimization, feed-forward control, or uncertainty quantification. For these uses, which require repeated model evaluations over a potentially large range of parameter values, a faster and more approximate model is needed. In this work, an efficient physics-based surrogate model for the L-PBF process is developed. A simplified-physics surrogate modeling approach is proposed in which the most important physical effect, heat conduction, is used as a foundation from which predictions are adjusted using experimental data and calibration. The efficiency of the heat conduction solution is improved through the development of a novel solution method for quickly predicting the thermal field produced from a heat source moving along an arbitrary path. The feasibility of the heat conduction foundation for a surrogate model is established by comparing to multiphysics high-fidelity simulations of the process. Using measurements of single track experiments, Bayesian inference is used to probabilistically calibrate model parameters, which allows the effect of un-modeled physics to be incorporated as well as the uncertainty in predictions to be quantified. The results of this work show that heat conduction itself is a reasonable approximation to the L-PBF process as long as adjustments are made, and it can be made flexible enough to be incorporated into a rigorous probabilistic framework for calibration and uncertainty quantification. The advances made in efficiency on arbitrary path thermal predictions provides a powerful tool for process optimization and scan strategy design. The developed framework for calibration and uncertainty quantification of single track predictions allows the construction of quick and useful predictive guidelines for building parts, such as defect identifying process maps. Overall, the impact of this work provides new insight and understanding into what is necessary and what is possible for an efficient and useful surrogate model of the L-PBF process.

Analysis of the Laser Powder Bed Fusion Additive Manufacturing Process Through Experimental Measurement and Finite Element Modeling

Download Analysis of the Laser Powder Bed Fusion Additive Manufacturing Process Through Experimental Measurement and Finite Element Modeling PDF Online Free

Author : Alexander Dunbar
Publisher :
ISBN 13 :
Total Pages : pages
Book Rating : 4.:/5 (951 download)

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Book Synopsis Analysis of the Laser Powder Bed Fusion Additive Manufacturing Process Through Experimental Measurement and Finite Element Modeling by : Alexander Dunbar

Download or read book Analysis of the Laser Powder Bed Fusion Additive Manufacturing Process Through Experimental Measurement and Finite Element Modeling written by Alexander Dunbar and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: The objective in this work is to provide rigourous experimental measurements to aid in the development of laser powder bed fusion (LPBF) additive manufacturing (AM). A specialized enclosed instrumented measurement system is designed to provide in situ experimental measurements of temperature and distortion. Experiments include comparisons of process parameters, materials and LPBF machines. In situ measurements of distortion and temperature made throughout the build process highlight inter-layer distortion effects previously undocumented for laser powder bed fusion. Results from these experiments are also be implemented in the development and validation of finite element models of the powder bed build process. Experimental analysis is extended from small-scale to larger part-scale builds where experimental post-build measurements are used in analysis of distortion profiles. Experimental results provided from this study are utilized in the validation of a finite element model capable of simulating production scale parts. The validated finite element model is then implemented in the analysis of the part to provide information regarding the distortion evolution process. A combination of experimental measurements and simulation results are used to identify the mechanism that results in the measured distortion profile for this geometry. Optimization of support structure primarily focuses on the minimization of material use and scan time, but no information regarding failure criteria for support structure is available. Tensile test samples of LPBF built support structure are designed, built, and tested to provide measurements of mechanical properties of the support structure. Experimental tests show that LPBF built support structure has only 30-40\% of the ultimate tensile strength of solid material built in the same machine. Experimental measurement of LPBF built support structure provides clear failure criteria to be utilized in the future design and implementation of support structure.

Digitalization of Design for Support Structures in Laser Powder Bed Fusion of Metals

Author : Katharina Bartsch
Publisher :
ISBN 13 : 9783031229572
Total Pages : 0 pages
Book Rating : 4.2/5 (295 download)

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Book Synopsis Digitalization of Design for Support Structures in Laser Powder Bed Fusion of Metals by : Katharina Bartsch

Download or read book Digitalization of Design for Support Structures in Laser Powder Bed Fusion of Metals written by Katharina Bartsch and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing is considered a key technology for digital production. However, several barriers towards the broad industrial application exist, e.g. the associated cost and the required experience regarding the manufacturing process. To eradicate these barriers, the complete digitalization of the value creation process is needed. In this thesis, a digital, automated support structure design procedure is developed. Topology optimization is used for design rule determination, and the space colonization algorithm is adapted for the automated design. The validity of the procedure is proven experimentally, revealing sufficient mechanical performance alongside cost reduction at medium to large production scales. The content Provides a concise review of support structure optimization in laser powder bed fusion Includes thermo-mechanical material model of Ti-6Al-4V alloy Contains cost model for calculation of support-induced costs The author Katharina Bartsch studied mechanical engineering with a focus on product development, materials and production at the Technical University of Hamburg. Here, she received her doctorate in 2022 under Prof. Dr.-Ing. Claus Emmelmann (Institute for Laser and System Technologies - iLAS). During her time as a doctoral candidate, she worked as a research associate as well as chief engineer (since 2020) at the iLAS and as a team leader and research associate (since 2019) at the LZN Laser Zentrum Nord GmbH, later Fraunhofer Research Institution for Additive Production Technologies IAPT.

Designing for Metal Additive Manufacturing

Author : Sai Nithin Reddy Kantareddy
Publisher :
ISBN 13 :
Total Pages : pages
Book Rating : 4.:/5 (959 download)

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Book Synopsis Designing for Metal Additive Manufacturing by : Sai Nithin Reddy Kantareddy

Download or read book Designing for Metal Additive Manufacturing written by Sai Nithin Reddy Kantareddy and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) offers unprecedented design freedom to produce complex designs in a single step. Laser-based powder bed fusion, in particular, is a promising metal AM process to fabricate complex metal parts that are otherwise difficult, costly, or impossible to manufacture using traditional means. Many techniques for lightweighting designs and improving part performance such as topology optimization, lattice structures, and part consolidation, often result in designs with complex features that can only be made with AM. Although AM is not necessarily constrained by this geometric complexity, it does require unsupported/overhanging features in the design to be structurally supported by additional structures that can be later removed by post-processing using various techniques such as hand tools, machining, wire EDM (Electrical Discharge Machining), etc. Depending on the complexity of the part, support structures can often be substantial, difficult to access, and complex in shape; therefore, removing the support structures may be very difficult and require multiple post-processing steps. As a result, overall manufacturing cost, material consumption, and manufacturing time may unnecessarily increase, making AM less economical than initially conceived. Additionally, the thermo-mechanical nature of the metal AM process induces residual stresses and distortions in the built parts. In-process distortions can lead to build failures, part curling and warping, and material waste. Therefore, many designs cannot be easily manufactured using AM or may actually cost more to produce with AM. Design for Additive Manufacturing (DfAM) can remedy these limitations. DfAM encompass a set of principles or guidelines based on theory and experience to help design parts to be manufactured easily with AM. Effective implementation of DfAM during the design phase can result in parts suitable for AM, which can be affordable to make and easier to produce. However, the strategies to implement DfAM principles are not generalized and vary from part to part, process to process, and material to material. These part-specific requirements may require modifications in the existing design workflow, and a single workflow may not be suitable for all the design cases. To understand some of these differences, this thesis focuses on investigating the design process for leveraging metal AM capabilities at different levels of design complexities by redesigning three industry relevant components for additive manufacturing. In each case, the design conceptualization, workflow, design tools, DfAM principles, and improvement in product performance are compared and contrasted. Based on these three cases, recommendations are made for improving the design tools, and ultimately for improving the design workflow to reduce the computation time and improve the information flow across the software platforms.

Additive manufacturing - Qualification principles - Qualifying machine operators of laser metal powder bed fusion machines and equipment used in aerospace applications

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Author :
Publisher :
ISBN 13 :
Total Pages : 0 pages
Book Rating : 4.:/5 (138 download)

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Book Synopsis Additive manufacturing - Qualification principles - Qualifying machine operators of laser metal powder bed fusion machines and equipment used in aerospace applications by :

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