Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys

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POYRAZ, Özgür ;KUŞHAN, Melih Cemal.
Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys. 
Strojniški vestnik - Journal of Mechanical Engineering, [S.l.], v. 65, n.6, p. 343-350, june 2019. 
ISSN 0039-2480.
Available at: <https://www.sv-jme.eu/article/residual-stress-induced-distortions-in-laser-powder-bed-additive-manufacturing-of-nickel-based-superalloys/>. Date accessed: 24 aug. 2019. 
doi:http://dx.doi.org/10.5545/sv-jme.2019.6004.
Poyraz, ., & Kuşhan, M.
(2019).
Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys.
Strojniški vestnik - Journal of Mechanical Engineering, 65(6), 343-350.
doi:http://dx.doi.org/10.5545/sv-jme.2019.6004
@article{sv-jmesv-jme.2019.6004,
	author = {Özgür  Poyraz and Melih Cemal Kuşhan},
	title = {Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys},
	journal = {Strojniški vestnik - Journal of Mechanical Engineering},
	volume = {65},
	number = {6},
	year = {2019},
	keywords = {additive manufacturing; finite element analysis; laser powder bed fusion; thermo-mechanical simulations},
	abstract = {One of the significant process limits of laser powder bed additive manufacturing technologies is residual stresses and distortions induced by heating the fine metal powder to the melting point and sudden cooling to the initial temperature. While this phenomenon applies to most types of metal alloys, it becomes more important in nickel-based superalloys, which have low thermal conductivity and high-quality requirements for aerospace utilization. Together with the mechanical integrity and geometric problems in the final product, residual stress-induced distortions carry the potential risk of interrupting the job process above a certain distortion limit as a result of part-to-re-coater rubbing. Process simulations performed in a computer environment are of critical importance to predict and to prevent this risk. However, simulation models need to be verified through experiments, and they need to be cost-effective in terms of simulation times. This paper presents a comprehensive study to introduce a fast thermo-mechanical simulation model, together with experiments on nickel-based superalloy demonstrators. It also contributes to the scientific knowledge base with novel coupon design, manufacturing and evaluation methodology for distortion studies.},
	issn = {0039-2480},	pages = {343-350},	doi = {10.5545/sv-jme.2019.6004},
	url = {https://www.sv-jme.eu/article/residual-stress-induced-distortions-in-laser-powder-bed-additive-manufacturing-of-nickel-based-superalloys/}
}
Poyraz, .,Kuşhan, M.
2019 June 65. Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys. Strojniški vestnik - Journal of Mechanical Engineering. [Online] 65:6
%A Poyraz, Özgür 
%A Kuşhan, Melih Cemal
%D 2019
%T Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys
%B 2019
%9 additive manufacturing; finite element analysis; laser powder bed fusion; thermo-mechanical simulations
%! Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys
%K additive manufacturing; finite element analysis; laser powder bed fusion; thermo-mechanical simulations
%X One of the significant process limits of laser powder bed additive manufacturing technologies is residual stresses and distortions induced by heating the fine metal powder to the melting point and sudden cooling to the initial temperature. While this phenomenon applies to most types of metal alloys, it becomes more important in nickel-based superalloys, which have low thermal conductivity and high-quality requirements for aerospace utilization. Together with the mechanical integrity and geometric problems in the final product, residual stress-induced distortions carry the potential risk of interrupting the job process above a certain distortion limit as a result of part-to-re-coater rubbing. Process simulations performed in a computer environment are of critical importance to predict and to prevent this risk. However, simulation models need to be verified through experiments, and they need to be cost-effective in terms of simulation times. This paper presents a comprehensive study to introduce a fast thermo-mechanical simulation model, together with experiments on nickel-based superalloy demonstrators. It also contributes to the scientific knowledge base with novel coupon design, manufacturing and evaluation methodology for distortion studies.
%U https://www.sv-jme.eu/article/residual-stress-induced-distortions-in-laser-powder-bed-additive-manufacturing-of-nickel-based-superalloys/
%0 Journal Article
%R 10.5545/sv-jme.2019.6004
%& 343
%P 8
%J Strojniški vestnik - Journal of Mechanical Engineering
%V 65
%N 6
%@ 0039-2480
%8 2019-06-21
%7 2019-06-21
Poyraz, Özgür, & Melih Cemal Kuşhan.
"Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys." Strojniški vestnik - Journal of Mechanical Engineering [Online], 65.6 (2019): 343-350. Web.  24 Aug. 2019
TY  - JOUR
AU  - Poyraz, Özgür 
AU  - Kuşhan, Melih Cemal
PY  - 2019
TI  - Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys
JF  - Strojniški vestnik - Journal of Mechanical Engineering
DO  - 10.5545/sv-jme.2019.6004
KW  - additive manufacturing; finite element analysis; laser powder bed fusion; thermo-mechanical simulations
N2  - One of the significant process limits of laser powder bed additive manufacturing technologies is residual stresses and distortions induced by heating the fine metal powder to the melting point and sudden cooling to the initial temperature. While this phenomenon applies to most types of metal alloys, it becomes more important in nickel-based superalloys, which have low thermal conductivity and high-quality requirements for aerospace utilization. Together with the mechanical integrity and geometric problems in the final product, residual stress-induced distortions carry the potential risk of interrupting the job process above a certain distortion limit as a result of part-to-re-coater rubbing. Process simulations performed in a computer environment are of critical importance to predict and to prevent this risk. However, simulation models need to be verified through experiments, and they need to be cost-effective in terms of simulation times. This paper presents a comprehensive study to introduce a fast thermo-mechanical simulation model, together with experiments on nickel-based superalloy demonstrators. It also contributes to the scientific knowledge base with novel coupon design, manufacturing and evaluation methodology for distortion studies.
UR  - https://www.sv-jme.eu/article/residual-stress-induced-distortions-in-laser-powder-bed-additive-manufacturing-of-nickel-based-superalloys/
@article{{sv-jme}{sv-jme.2019.6004},
	author = {Poyraz, ., Kuşhan, M.},
	title = {Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys},
	journal = {Strojniški vestnik - Journal of Mechanical Engineering},
	volume = {65},
	number = {6},
	year = {2019},
	doi = {10.5545/sv-jme.2019.6004},
	url = {https://www.sv-jme.eu/article/residual-stress-induced-distortions-in-laser-powder-bed-additive-manufacturing-of-nickel-based-superalloys/}
}
TY  - JOUR
AU  - Poyraz, Özgür 
AU  - Kuşhan, Melih Cemal
PY  - 2019/06/21
TI  - Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys
JF  - Strojniški vestnik - Journal of Mechanical Engineering; Vol 65, No 6 (2019): Strojniški vestnik - Journal of Mechanical Engineering
DO  - 10.5545/sv-jme.2019.6004
KW  - additive manufacturing, finite element analysis, laser powder bed fusion, thermo-mechanical simulations
N2  - One of the significant process limits of laser powder bed additive manufacturing technologies is residual stresses and distortions induced by heating the fine metal powder to the melting point and sudden cooling to the initial temperature. While this phenomenon applies to most types of metal alloys, it becomes more important in nickel-based superalloys, which have low thermal conductivity and high-quality requirements for aerospace utilization. Together with the mechanical integrity and geometric problems in the final product, residual stress-induced distortions carry the potential risk of interrupting the job process above a certain distortion limit as a result of part-to-re-coater rubbing. Process simulations performed in a computer environment are of critical importance to predict and to prevent this risk. However, simulation models need to be verified through experiments, and they need to be cost-effective in terms of simulation times. This paper presents a comprehensive study to introduce a fast thermo-mechanical simulation model, together with experiments on nickel-based superalloy demonstrators. It also contributes to the scientific knowledge base with novel coupon design, manufacturing and evaluation methodology for distortion studies.
UR  - https://www.sv-jme.eu/article/residual-stress-induced-distortions-in-laser-powder-bed-additive-manufacturing-of-nickel-based-superalloys/
Poyraz, Özgür, AND Kuşhan, Melih.
"Residual Stress-induced Distortions in Laser Powder Bed Additive Manufacturing of Nickel-based Superalloys" Strojniški vestnik - Journal of Mechanical Engineering [Online], Volume 65 Number 6 (21 June 2019)

Authors

Affiliations

  • TEI, Tusaş Engine Industries, Inc., Turkey
  • Eskişehir Osmangazi University, Faculty of Engineering, Department of Mechanical Engineering, Turkey

Paper's information

Strojniški vestnik - Journal of Mechanical Engineering 65(2019)6, 343-350

10.5545/sv-jme.2019.6004

One of the significant process limits of laser powder bed additive manufacturing technologies is residual stresses and distortions induced by heating the fine metal powder to the melting point and sudden cooling to the initial temperature. While this phenomenon applies to most types of metal alloys, it becomes more important in nickel-based superalloys, which have low thermal conductivity and high-quality requirements for aerospace utilization. Together with the mechanical integrity and geometric problems in the final product, residual stress-induced distortions carry the potential risk of interrupting the job process above a certain distortion limit as a result of part-to-re-coater rubbing. Process simulations performed in a computer environment are of critical importance to predict and to prevent this risk. However, simulation models need to be verified through experiments, and they need to be cost-effective in terms of simulation times. This paper presents a comprehensive study to introduce a fast thermo-mechanical simulation model, together with experiments on nickel-based superalloy demonstrators. It also contributes to the scientific knowledge base with novel coupon design, manufacturing and evaluation methodology for distortion studies.

additive manufacturing; finite element analysis; laser powder bed fusion; thermo-mechanical simulations