Mikula, J., Ahluwalia, R., Louis Commillus, A., Ren, K., Chew, Y., Vastola, G., & Zhang, Y.-W. (2024). The role of tool path on microstructure uniformity in large-format additive manufacturing: integrated thermo-metallurgical-mechanical approach. International Journal of Computer Integrated Manufacturing, 1–22. https://doi.org/10.1080/0951192x.2024.2314783
Abstract:
Directed energy deposition (DED) of large metal components has clear potential to revolutionise supply chains in several sectors, including marine & offshore and oil &; gas. To insert this technology
in production, ensuring part quality and consistency is of primary importance. However, such insertion is hindered by bottleneck issues arising from the manufacturing process, including part
distortion and non-uniform mechanical properties. To address this important industrial need, an integrated thermo-metallurgical-mechanical numerical model capable of directly reading the
robot tool-path (g-code) as well as the component shape, is here developed in-house and tailored
to steel EH36, which is of particular relevance to the marine, offshore and oil &; gas sectors. The
model computes temperature at part scale, microstructure (phase fraction distribution) and
residual stress and distortion, where each step of the chain is informed by the previous one.
After demonstrating the framework on a single bead and thin wall geometries, the framework is
applied to investigate the role of tool path in printing a more complex geometry. The presented
framework allows to digitally correlate part design, process parameters, and tool path with
microstructure distribution, residual stresses, and distortion, supporting digital process development
in DED of large metal components.
License type:
Attribution-NonCommercial-NoDerivatives 4.0 International (CC BY-NC-ND 4.0)
Funding Info:
This research / project is supported by the A*STAR - Advanced Models for Additive Manufacturing (AM2)
Grant Reference no. : M22L2b0111
This research / project is supported by the A*STAR - Integrated Large Format Hybrid Manufacturing using Wirefed and Powder-blown Technology for LAAM process
Grant Reference no. : A1893a0031
This research / project is supported by the A*STAR - Industrial Digital Design and Additive Manufacturing Workflows
Grant Reference no. : A19E1a0097
Description:
This is an Accepted Manuscript of an article published by Taylor & Francis in International Journal of Computer Integrated Manufacturing on 05 Mar 2024, available online: http://www.tandfonline.com/doi/full/10.1080/0951192X.2024.2314783