The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting

The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along...

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Main Authors: Yan, Zhiqiang, Wu, Kaiwen, Xiao, Zhongmin, Hui, Jizhuang, Lv, Jingxiang
Other Authors: School of Mechanical and Aerospace Engineering
Format: Article
Language:English
Published: 2024
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Online Access:https://hdl.handle.net/10356/180594
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Institution: Nanyang Technological University
Language: English
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spelling sg-ntu-dr.10356-1805942024-10-19T16:48:52Z The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting Yan, Zhiqiang Wu, Kaiwen Xiao, Zhongmin Hui, Jizhuang Lv, Jingxiang School of Mechanical and Aerospace Engineering Engineering Damping alloy Selective laser melting The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along which the laser head scans powders within given area, is crucial, but clearly defined criteria for scanning strategy design are lacking. In this study, a three-dimensional finite element model (FEM) of the SLM process for manufacturing a WE43 alloy component was established and validated against the published experimental data. Eleven different scanning strategies were designed and simulated, considering variables such as scanning track length, direction, Out–In or In–Out strategy, start point, and interlayer variation. The results showed that scanning strategy, geometry, and layer number collectively affect temperature, melt pool, and stress outputs. For instance, starting scanning at a colder part of the powder layer could lead to a high peak temperature and low melt pool depth. A higher layer number generally results in lower cooling rate, a lower temperature gradient, a longer melt pool life, and larger melt pool dimensions. Changing the start point between scanning circulations helps mitigate detrimental residual stress. This work highlights the potential of analyzing various scanning strategy-related variables, which contributes to reducing trial-and-error tests and selecting optimal scanning strategies under different product quality requirements. This article can assist in the design of appropriate scanning strategies to prevent defects such as element loss due to evaporation, poor bonding, and deformation or cracking from high residual stress. Additionally, identifying stress concentration locations and understanding the effects of geometry and layer number on thermal and mechanical behaviors can assist in geometry design. Published version This study is supported by the China Scholarship Council [CSC No. 202206560023] and Scientific Innovation Practice Project of Postgraduates of Chang’an University [300103724009]. 2024-10-14T05:57:11Z 2024-10-14T05:57:11Z 2024 Journal Article Yan, Z., Wu, K., Xiao, Z., Hui, J. & Lv, J. (2024). The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting. Materials, 17(12), 2912-. https://dx.doi.org/10.3390/ma17122912 1996-1944 https://hdl.handle.net/10356/180594 10.3390/ma17122912 2-s2.0-85197234947 12 17 2912 en Materials © 2024 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https:// creativecommons.org/licenses/by/ 4.0/). application/pdf
institution Nanyang Technological University
building NTU Library
continent Asia
country Singapore
Singapore
content_provider NTU Library
collection DR-NTU
language English
topic Engineering
Damping alloy
Selective laser melting
spellingShingle Engineering
Damping alloy
Selective laser melting
Yan, Zhiqiang
Wu, Kaiwen
Xiao, Zhongmin
Hui, Jizhuang
Lv, Jingxiang
The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
description The manufacture of damping alloy parts with stable damping properties and high mechanical performances in the selective laser melting (SLM) process is influenced by temperature evolution and residual stress distribution. Choosing an appropriate scanning strategy, namely the specific trajectory along which the laser head scans powders within given area, is crucial, but clearly defined criteria for scanning strategy design are lacking. In this study, a three-dimensional finite element model (FEM) of the SLM process for manufacturing a WE43 alloy component was established and validated against the published experimental data. Eleven different scanning strategies were designed and simulated, considering variables such as scanning track length, direction, Out–In or In–Out strategy, start point, and interlayer variation. The results showed that scanning strategy, geometry, and layer number collectively affect temperature, melt pool, and stress outputs. For instance, starting scanning at a colder part of the powder layer could lead to a high peak temperature and low melt pool depth. A higher layer number generally results in lower cooling rate, a lower temperature gradient, a longer melt pool life, and larger melt pool dimensions. Changing the start point between scanning circulations helps mitigate detrimental residual stress. This work highlights the potential of analyzing various scanning strategy-related variables, which contributes to reducing trial-and-error tests and selecting optimal scanning strategies under different product quality requirements. This article can assist in the design of appropriate scanning strategies to prevent defects such as element loss due to evaporation, poor bonding, and deformation or cracking from high residual stress. Additionally, identifying stress concentration locations and understanding the effects of geometry and layer number on thermal and mechanical behaviors can assist in geometry design.
author2 School of Mechanical and Aerospace Engineering
author_facet School of Mechanical and Aerospace Engineering
Yan, Zhiqiang
Wu, Kaiwen
Xiao, Zhongmin
Hui, Jizhuang
Lv, Jingxiang
format Article
author Yan, Zhiqiang
Wu, Kaiwen
Xiao, Zhongmin
Hui, Jizhuang
Lv, Jingxiang
author_sort Yan, Zhiqiang
title The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
title_short The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
title_full The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
title_fullStr The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
title_full_unstemmed The effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
title_sort effect of scanning strategy on the thermal behavior and residual stress distribution of damping alloys during selective laser melting
publishDate 2024
url https://hdl.handle.net/10356/180594
_version_ 1814777778064588800