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Effect of pre-emptive in situ parameter modification on residual stress distributions within selective laser-melted Ti6Al4V components

Ali, Haider; Ghadbeigi, Hassan; Hosseinzadeh, Foroogh; de Oliveira, Jeferson and Mumtaz, Kamran (2019). Effect of pre-emptive in situ parameter modification on residual stress distributions within selective laser-melted Ti6Al4V components. The International Journal of Advanced Manufacturing Technology, 103(9-12) pp. 4467–4479.

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DOI (Digital Object Identifier) Link: https://doi.org/10.1007/s00170-019-03860-6
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Abstract

The effect of thermally induced residual stresses is not dynamically considered during a selective laser melting (SLM) build; instead, it processes using invariable parameters across the entire component’s cross-section. This lack of pre-emptive in situ parameter adjustment to reduce residual stresses during processing is a lost opportunity for the process with the potential to improve component mechanical properties. This investigation studied the residual stresses introduced during manufacturing of SLM Ti6Al4V benchmark components and adapted process parameters within a build (layer-to-layer specific modifications) to manage and redistribute stresses within these components. It was found that temporarily switching to an increased layer thickness during the build, directly below highly stressed regions within the component, redistributed stresses and reduced the overall stresses within the structure by 8.5% (within the 80–320-MPa residual stress range) compared to standard invariable SLM processing parameters. This work demonstrates the need for current SLM systems to focus on developing a more intelligent processing architecture with parameters that adapt on the fly during a build, in order to manage residual stresses within the built structure.

Item Type: Journal Item
Copyright Holders: 2019 The Authors
ISSN: 0268-3768
Keywords: Residual stress; Geometrical dependence; Cooling rate; Selective laser melting; Additive manufacturing; Ti6Al4V
Academic Unit/School: Faculty of Science, Technology, Engineering and Mathematics (STEM) > Engineering and Innovation
Faculty of Science, Technology, Engineering and Mathematics (STEM)
Item ID: 61979
Depositing User: ORO Import
Date Deposited: 19 Jun 2019 09:10
Last Modified: 06 Aug 2019 07:23
URI: http://oro.open.ac.uk/id/eprint/61979
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