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Numerical Evaluation of Advanced Laser Control Strategies Influence on Residual Stresses for Laser Powder Bed Fusion Systems

Published

Author(s)

Carraturo Massimo, Brandon Lane, Ho Yeung, Stefan Kollmannsberger, Alessandro Reali, Ferdinando Auricchio

Abstract

Process-dependent residual stresses are one of the main burdens to a wide spread adoption of laser powder bed fusion technology in industry. Residual stresses are directly influenced by process parameters, such as laser path, laser power, and speed. In this work, the influence of various scan speed and laser power control strategies on residual stresses is investigated. A set of nine different laser scan patterns is 3D printed on a bare plate of nickel superalloy 625 (IN625). A finite element model is experimentally validated comparing the simulated melt-pool areas with high-speed thermal camera in-situ measurements. Finite element analysis is then used to evaluate residual stresses for the nine different laser scan control strategies, in order to identify the strategy which minimizes the residual stress magnitude. Numerical results show that a constant power density scan strategy appears the most effective to reduce residual stresses in the considered domain.
Citation
Integrating Materials and Manufacturing Innovation

Keywords

Selective laser melting, finite cell method, residual stress, thermomechanical analysis

Citation

Massimo, C. , Lane, B. , Yeung, H. , Kollmannsberger, S. , Reali, A. and Auricchio, F. (2020), Numerical Evaluation of Advanced Laser Control Strategies Influence on Residual Stresses for Laser Powder Bed Fusion Systems, Integrating Materials and Manufacturing Innovation, [online], https://doi.org/10.1007/s40192-020-00191-3, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=931066 (Accessed July 6, 2022)
Created November 30, 2020, Updated February 23, 2022