More Like this

1. Effects of Inter-Layer Time Interval on Temperature Gradients in Direct Laser Deposited Ti-6Al-4V

   Masoomi, M. ; Thompson, S.M. ; Shamsaei, N. ; Bian, L. ( August 2016 , Annual International Solid Freeform Fabrication Symposium)

   Parts fabricated via additive manufacturing (AM) methods are prone to experiencing high temperature gradients during manufacture resulting in internal residual stress formation. In the current study, a numerical model for predicting the temperature distribution and residual stress in Directed Energy Deposited (DED) Ti–6Al–4V parts is utilized for determining a relationship between local part temperature gradients with generated residual stress. Effects of time interval between successive layer deposits, as well as layer deposition itself, on the temperature gradient vector for the first and each layer is investigated. The numerical model is validated using thermographic measurements of Ti-6Al-4V specimens fabricated via Laser Engineered Net Shaping® (LENS), a blown-powder/laser-based DED method. Results demonstrate the heterogeneity in the part’s spatiotemporal temperature field, and support the fact that as the part number, or single part size or geometry, vary, the resultant residual stress due to temperature gradients will be impacted. As the time inter-layer time interval increases from 0 to 10 second, the temperature gradient magnitude in vicinity of the melt pool will increase slightly.
2. Measurement of Intrinsic Residual Stresses in 3D Woven Composites Using Measurement of the Displacement Fields from Hole Drilling by Electronic Speckle Pattern Interferometry and Digital Image Correlation

   https://doi.org/10.12783/asc33/26127  

   GROSS, TODD ; BUNTROCK, HILARY ; TSUKROV, IGOR ; DRACH, BORYS ; VASYLEVSKYI, KOSTIANTYN ; CHAGNON, NICHOLAS ( November 2018 , Measurement of Intrinsic Residual Stresses in 3D Woven Composites Using Measurement of the Displacement Fields from Hole Drilling by Electronic Speckle Pattern Interferometry and Digital Image Correlation)

   Intrinsic residual stresses in woven composites result from the coefficient of thermal expansion mismatch between the fibers and the matrix. Extrinsic residual stresses result from large scale thermal gradients during curing and cooling. Intrinsic residual stresses in 3D woven composites are sometimes severe enough to cause micro-cracking in the matrix. They are also expected to impact the fatigue resistance and the impact resistance. To the best of our knowledge, there have been no spatially resolved measurements of the intrinsic residual stress field as a function of position in the repeating weave pattern. We used digital image correlation (DIC) and electronic speckle pattern interferometry (ESPI) to measure the surface displacement field resulting from drilling a 1 mm diameter hole at four selected locations in two different 3D woven composite architectures that represent low and high through-the-thickness constraint. The two methods are used because the displacements sometimes on the lower end of the resolution for the DIC method and the displacement gradients are sometimes too steep to resolve the fringes for the ESPI method. Finite element models constructed with realistic fiber geometry using Dynamic Fabric Mechanic Analyzer software were utilized to estimate the residual stress field from cooling from the curing temperature.more »Holes were manually inserted by deactivating the elements in the hole region and the resultant displacement fields were compared to the measurements. In general, the measured displacement fields were lower in magnitude than the model predictions. In some cases, the sign of the predicted displacement field is opposite to the observed field which could be attributed to differences between the actual hole location and the hole in the model.« less
3. Thermal Modeling in Metal Additive Manufacturing Using Graph Theory

   https://doi.org/10.1115/1.4043648  

   Yavari, M. Reza ; Cole, Kevin D. ; Rao, Prahalada ( July 2019 , Journal of Manufacturing Science and Engineering)

   The goal of this work is to predict the effect of part geometry and process parameters on the instantaneous spatiotemporal distribution of temperature, also called the thermal field or temperature history, in metal parts as they are being built layer-by-layer using additive manufacturing (AM) processes. In pursuit of this goal, the objective of this work is to develop and verify a graph theory-based approach for predicting the temperature distribution in metal AM parts. This objective is consequential to overcome the current poor process consistency and part quality in AM. One of the main reasons for poor part quality in metal AM processes is ascribed to the nature of temperature distribution in the part. For instance, steep thermal gradients created in the part during printing leads to defects, such as warping and thermal stress-induced cracking. Existing nonproprietary approaches to predict the temperature distribution in AM parts predominantly use mesh-based finite element analyses that are computationally tortuous—the simulation of a few layers typically requires several hours, if not days. Hence, to alleviate these challenges in metal AM processes, there is a need for efficient computational models to predict the temperature distribution, and thereby guide part design and selection of process parameters insteadmore »of expensive empirical testing. Compared with finite element analyses techniques, the proposed mesh-free graph theory-based approach facilitates prediction of the temperature distribution within a few minutes on a desktop computer. To explore these assertions, we conducted the following two studies: (1) comparing the heat diffusion trends predicted using the graph theory approach with finite element analysis, and analytical heat transfer calculations based on Green’s functions for an elementary cuboid geometry which is subjected to an impulse heat input in a certain part of its volume and (2) simulating the laser powder bed fusion metal AM of three-part geometries with (a) Goldak’s moving heat source finite element method, (b) the proposed graph theory approach, and (c) further comparing the thermal trends predicted from the last two approaches with a commercial solution. From the first study, we report that the thermal trends approximated by the graph theory approach are found to be accurate within 5% of the Green’s functions-based analytical solution (in terms of the symmetric mean absolute percentage error). Results from the second study show that the thermal trends predicted for the AM parts using graph theory approach agree with finite element analyses, and the computational time for predicting the temperature distribution was significantly reduced with graph theory. For instance, for one of the AM part geometries studied, the temperature trends were predicted in less than 18 min within 10% error using the graph theory approach compared with over 180 min with finite element analyses. Although this paper is restricted to theoretical development and verification of the graph theory approach, our forthcoming research will focus on experimental validation through in-process thermal measurements.« less
4. Influence of Temperature-Dependent Resin Behavior on Numerical Prediction of Effective CTEs of 3D Woven Composites

   https://doi.org/10.12783/asc36/35938  

   Vasylevskyi, Kostiantyn ; Drach, Borys ; Tsukrov, Igor ( September 2021 , Proceedings of the 36th ASC Technical Conference, College Station, TX, USA, 2021)

   3D woven composites are well known for their high strength, dimensional stability, delamination, and impact resistance. They are often used in aerospace, energy, and automotive industries where material parts can experience harsh service conditions including substantial variations in temperature. This may lead to significant thermal deformations and thermally-induced stresses in the material. Additionally, 3D woven composites are often produced using resin transfer molding (RTM) technique which involves curing the epoxy resin at elevated temperatures leading to accumulation of the processing-induced residual stress. Thus, understanding of effective thermal behavior of 3D woven composites is essential for their successful design and service. In this paper, the effective thermal properties of 3D woven carbon-epoxy composite materials are estimated using mesoscale finite element models previously developed for evaluation of the manufacturing-induced residual stresses. We determine effective coefficients of thermal expansion (CTEs) of the composites in terms of the known thermal and mechanical properties of epoxy resin and carbon fibers. We investigate how temperature sensitivity of the thermal and mechanical properties of the epoxy influences the overall thermal properties of the composite. The simulations are performed for different composite reinforcement morphologies including ply-to-ply and orthogonal. It is shown that even linear dependence of epoxy’s stiffnessmore »and CTE on temperature results in a nonlinear dependence on temperature of the overall composite’s CTE.« less
5. The Effect of Bulk Residual Stress on Milling-Induced Residual Stress and Distortion

   https://doi.org/10.1007/s11340-022-00843-9  

   Chighizola, C. R. ; D’Elia, C. R. ; Jonsson, J. E. ; Weber, D. ; Kirsch, B. ; Aurich, J. C. ; Linke, B. S. ; Hill, M. R. ( April 2022 , Experimental Mechanics)

   Distortion arises during machining of metallic parts from two main mechanisms: 1) release of bulk residual stress (BRS) in the pre-form, and 2) permanent deformation induced by cut tools. Interaction between these mechanisms is unexplored.

   Assess this interaction using aluminum samples that have a flat surface with variations of BRS, where that surface is subsequently milled, and we observe milling-induced residual stress (MIRS) and distortion.

   Plate samples are cut from two kinds of large blocks, one kind stress-relieved by stretching and a second kind solution heat treated, quenched and aged. The BRS field in the plates is known from a recent series of measurements, being small in the stress relieved plates (within ±20 MPa) and large (±100 MPa) in the quenched plates, varying from tension to compression over the surface that is milled. MIRS is measured following milling using hole-drilling. Distortions of thin wafers cut at the milled surfaces are used to elucidate BRS/MIRS interactions. A finite element (FE) model and a strength of materials model are each used to assess consistency between wafer distortion and measured MIRS.

   Milling in samples with high BRS magnitude changes the directions of MIRS and distortion relative to the milling direction, with the direction ofmore »maximum curvature rotating toward or away from the milling direction depending on the sign and direction of BRS. High magnitude BRS was also found to increase the wafer peak arc height, nearly doubling the amount found in low BRS samples.

   Measured residual stress and observed wafer distortion both show interactions between MIRS and BRS. Stress analysis models show that the differences in measured MIRS are consistent with the differences in observed distortion.

   « less