Effect of Scanning Strategy on Thermal Stresses and Strains during Electron Beam Melting of Inconel 625: Experiment and Simulation

This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at high temperatures. The bending and rupture of trusses supporting Inconel 625 alloy panels at ~1050 °C are experimentally measured for various...

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Published inMaterials Vol. 16; no. 1; p. 443
Main Authors Zhao, Xiaoyu, Wei, Yuan, Mansour, Rami, Dadbakhsh, Sasan, Rashid, Amir
Format Journal Article
LanguageEnglish
Published Switzerland MDPI AG 01.01.2023
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Abstract This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at high temperatures. The bending and rupture of trusses supporting Inconel 625 alloy panels at ~1050 °C are experimentally measured for various scanning strategies. The generated thermal stresses and strains are thereafter simulated using the Finite-Element Method (FEM). It is shown that the thermal stresses on the trusses may reach the material UTS without causing failure. Failure is only reached after the part experiences a certain magnitude of plastic strain (~0.33 ± 0.01 here). As the most influential factor, the plastic strain increases with the scanning length. In addition, it is shown that continuous scanning is necessary since the interrupted chessboard strategy induces cracking at the overlapping regions. Therefore, the associated thermal deformation is to be minimized using a proper layer rotation according to the part length. Although this is similar to the literature reported for selective laser melting (SLM), the effect of scanning pattern is found to differ, as no significant difference in thermal stresses/strains is observed between bidirectional and unidirectional patterns from EBM.
AbstractList This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at high temperatures. The bending and rupture of trusses supporting Inconel 625 alloy panels at ~1050 °C are experimentally measured for various scanning strategies. The generated thermal stresses and strains are thereafter simulated using the Finite-Element Method (FEM). It is shown that the thermal stresses on the trusses may reach the material UTS without causing failure. Failure is only reached after the part experiences a certain magnitude of plastic strain (~0.33 ± 0.01 here). As the most influential factor, the plastic strain increases with the scanning length. In addition, it is shown that continuous scanning is necessary since the interrupted chessboard strategy induces cracking at the overlapping regions. Therefore, the associated thermal deformation is to be minimized using a proper layer rotation according to the part length. Although this is similar to the literature reported for selective laser melting (SLM), the effect of scanning pattern is found to differ, as no significant difference in thermal stresses/strains is observed between bidirectional and unidirectional patterns from EBM.
This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at high temperatures. The bending and rupture of trusses supporting Inconel 625 alloy panels at ~1050 °C are experimentally measured for various scanning strategies. The generated thermal stresses and strains are thereafter simulated using the Finite-Element Method (FEM). It is shown that the thermal stresses on the trusses may reach the material UTS without causing failure. Failure is only reached after the part experiences a certain magnitude of plastic strain (~0.33 ± 0.01 here). As the most influential factor, the plastic strain increases with the scanning length. In addition, it is shown that continuous scanning is necessary since the interrupted chessboard strategy induces cracking at the overlapping regions. Therefore, the associated thermal deformation is to be minimized using a proper layer rotation according to the part length. Although this is similar to the literature reported for selective laser melting (SLM), the effect of scanning pattern is found to differ, as no significant difference in thermal stresses/strains is observed between bidirectional and unidirectional patterns from EBM.This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at high temperatures. The bending and rupture of trusses supporting Inconel 625 alloy panels at ~1050 °C are experimentally measured for various scanning strategies. The generated thermal stresses and strains are thereafter simulated using the Finite-Element Method (FEM). It is shown that the thermal stresses on the trusses may reach the material UTS without causing failure. Failure is only reached after the part experiences a certain magnitude of plastic strain (~0.33 ± 0.01 here). As the most influential factor, the plastic strain increases with the scanning length. In addition, it is shown that continuous scanning is necessary since the interrupted chessboard strategy induces cracking at the overlapping regions. Therefore, the associated thermal deformation is to be minimized using a proper layer rotation according to the part length. Although this is similar to the literature reported for selective laser melting (SLM), the effect of scanning pattern is found to differ, as no significant difference in thermal stresses/strains is observed between bidirectional and unidirectional patterns from EBM.
This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at high temperatures. The bending and rupture of trusses supporting Inconel 625 alloy panels at similar to 1050 degrees C are experimentally measured for various scanning strategies. The generated thermal stresses and strains are thereafter simulated using the Finite-Element Method (FEM). It is shown that the thermal stresses on the trusses may reach the material UTS without causing failure. Failure is only reached after the part experiences a certain magnitude of plastic strain (similar to 0.33 +/- 0.01 here). As the most influential factor, the plastic strain increases with the scanning length. In addition, it is shown that continuous scanning is necessary since the interrupted chessboard strategy induces cracking at the overlapping regions. Therefore, the associated thermal deformation is to be minimized using a proper layer rotation according to the part length. Although this is similar to the literature reported for selective laser melting (SLM), the effect of scanning pattern is found to differ, as no significant difference in thermal stresses/strains is observed between bidirectional and unidirectional patterns from EBM.
Audience Academic
Author Dadbakhsh, Sasan
Wei, Yuan
Rashid, Amir
Mansour, Rami
Zhao, Xiaoyu
AuthorAffiliation 2 Frontiers Science Center for Flexible Electronics, Xi’an Institute of Flexible Electronics (IFE), Xi’an Institute of Biomedical Materials & Engineering, Northwestern Polytechnical University, Xi’an 710072, China
1 Department of Production Engineering, KTH Royal Institute of Technology, Brinellvägen 68, 11428 Stockholm, Sweden
3 Department of Engineering Mechanics, KTH Royal Institute of Technology, Teknikringen 8D, 10044 Stockholm, Sweden
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Issue 1
Keywords electron beam melting (EBM)
additive manufacturing
thermal distortion
scanning strategy
simulation
Language English
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Snippet This paper develops a hybrid experimental/simulation method for the first time to assess the thermal stresses generated during electron beam melting (EBM) at...
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StartPage 443
SubjectTerms additive manufacturing
additive manufacturing simulation
Deformation
Electron beam melting
electron beam melting (EBM)
Energy
Experiments
Finite element method
Heat resistant alloys
High temperature
Hypotheses
Laser beam melting
Nickel alloys
Nickel base alloys
Plastic deformation
Residual stress
Scanning
scanning strategy
Simulation
Stainless steel
Strain
Superalloys
Temperature
thermal distortion
Thermal stress
Trusses
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Title Effect of Scanning Strategy on Thermal Stresses and Strains during Electron Beam Melting of Inconel 625: Experiment and Simulation
URI https://www.ncbi.nlm.nih.gov/pubmed/36614787
https://www.proquest.com/docview/2761192756
https://www.proquest.com/docview/2761980119
https://pubmed.ncbi.nlm.nih.gov/PMC9822210
https://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-323428
https://doaj.org/article/d700f02a0b0143b380fee75987282dff
Volume 16
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