Crack-free laser powder bed fusion by substrate design

Additively manufactured components by laser powder bed fusion (LPBF) often suffer from stress-induced cracks (e.g. delamination), especially at the build-substrate interfaces where stiff mechanical constraints and large thermal gradients coexist. To reduce the probability of cracking, this work prop...

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Autores: Lu, Xufei|||0000-0002-5829-385X, Zhang, Wenyou, Chiumenti, Michele|||0000-0002-6286-7393, Cervera Ruiz, Miguel|||0000-0003-3437-6703
Tipo de recurso: artículo
Fecha de publicación:2022
País:España
Institución:Universitat Politècnica de Catalunya (UPC)
Repositorio:UPCommons. Portal del coneixement obert de la UPC
Idioma:inglés
OAI Identifier:oai:upcommons.upc.edu:2117/373089
Acceso en línea:https://hdl.handle.net/2117/373089
https://dx.doi.org/10.1016/j.addma.2022.103149
Access Level:acceso abierto
Palabra clave:Manufacturing processes
Laser powder bed fusion
Cracking
Structural optimization
Thermomechanical simulation
Fabricació
Àrees temàtiques de la UPC::Enginyeria dels materials::Metal·lúrgia
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spelling Crack-free laser powder bed fusion by substrate designLu, Xufei|||0000-0002-5829-385XZhang, WenyouChiumenti, Michele|||0000-0002-6286-7393Cervera Ruiz, Miguel|||0000-0003-3437-6703Manufacturing processesLaser powder bed fusionCrackingStructural optimizationThermomechanical simulationFabricacióÀrees temàtiques de la UPC::Enginyeria dels materials::Metal·lúrgiaAdditively manufactured components by laser powder bed fusion (LPBF) often suffer from stress-induced cracks (e.g. delamination), especially at the build-substrate interfaces where stiff mechanical constraints and large thermal gradients coexist. To reduce the probability of cracking, this work proposes an innovative strategy to optimize the geometry of the substrate by reducing its mechanical stiffness and, consequently, the stress accumulation during LPBF. To assess the feasibility of the strategy, a coupled thermo-mechanical finite element model, calibrated with the experimental evidence obtained from the LPBF metal deposition of a bridge-type structure, is used to predict the thermo-mechanical behavior of two T-shape AM parts built on (i) a typical solid substrate and (ii) a groove patterned substrate, respectively. The results show that several visible cracks appear at the interface between the build and the typical solid substrate due to stress concentration (up to 1600 MPa), while a crack-free component can be manufactured by adding grooves through the thickness of the substrate, without compromising the resulting microstructure and microhardness of the metallic materials with high crack sensitivity. The difference between the groove patterned substrate design with respect to the use of support structures used for printing cantilever structures is clarified to further justify the novelty of the proposed approach.This work was funded by the Enterprise Ireland project (No. CF-2020–1564-A/B), the National Key R&D Program of China (No. 2016YFB1100100), the European KYKLOS 4.0 project (No. 872570) and the China Scholarship Council (No. 201906290011). The authors also acknowledge the AR-Lab and the AML in TCD.Peer ReviewedElsevier20222022-11-0120222022-09-20journal articlehttp://purl.org/coar/resource_type/c_6501VoRhttp://purl.org/coar/version/c_970fb48d4fbd8a85info:eu-repo/semantics/articleapplication/pdfhttps://hdl.handle.net/2117/373089https://dx.doi.org/10.1016/j.addma.2022.103149reponame:UPCommons. Portal del coneixement obert de la UPCinstname:Universitat Politècnica de Catalunya (UPC)InglésengEuropean Commission http://doi.org/10.13039/100010661 Horizon 2020 Framework Programme 872570 An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferencesopen accesshttp://purl.org/coar/access_right/c_abf2Attribution-NonCommercial-NoDerivatives 4.0 Internationalhttp://creativecommons.org/licenses/by-nc-nd/4.0/info:eu-repo/semantics/openAccessoai:upcommons.upc.edu:2117/3730892026-05-27T15:37:01Z
dc.title.none.fl_str_mv Crack-free laser powder bed fusion by substrate design
title Crack-free laser powder bed fusion by substrate design
spellingShingle Crack-free laser powder bed fusion by substrate design
Lu, Xufei|||0000-0002-5829-385X
Manufacturing processes
Laser powder bed fusion
Cracking
Structural optimization
Thermomechanical simulation
Fabricació
Àrees temàtiques de la UPC::Enginyeria dels materials::Metal·lúrgia
title_short Crack-free laser powder bed fusion by substrate design
title_full Crack-free laser powder bed fusion by substrate design
title_fullStr Crack-free laser powder bed fusion by substrate design
title_full_unstemmed Crack-free laser powder bed fusion by substrate design
title_sort Crack-free laser powder bed fusion by substrate design
dc.creator.none.fl_str_mv Lu, Xufei|||0000-0002-5829-385X
Zhang, Wenyou
Chiumenti, Michele|||0000-0002-6286-7393
Cervera Ruiz, Miguel|||0000-0003-3437-6703
author Lu, Xufei|||0000-0002-5829-385X
author_facet Lu, Xufei|||0000-0002-5829-385X
Zhang, Wenyou
Chiumenti, Michele|||0000-0002-6286-7393
Cervera Ruiz, Miguel|||0000-0003-3437-6703
author_role author
author2 Zhang, Wenyou
Chiumenti, Michele|||0000-0002-6286-7393
Cervera Ruiz, Miguel|||0000-0003-3437-6703
author2_role author
author
author
dc.subject.none.fl_str_mv Manufacturing processes
Laser powder bed fusion
Cracking
Structural optimization
Thermomechanical simulation
Fabricació
Àrees temàtiques de la UPC::Enginyeria dels materials::Metal·lúrgia
topic Manufacturing processes
Laser powder bed fusion
Cracking
Structural optimization
Thermomechanical simulation
Fabricació
Àrees temàtiques de la UPC::Enginyeria dels materials::Metal·lúrgia
description Additively manufactured components by laser powder bed fusion (LPBF) often suffer from stress-induced cracks (e.g. delamination), especially at the build-substrate interfaces where stiff mechanical constraints and large thermal gradients coexist. To reduce the probability of cracking, this work proposes an innovative strategy to optimize the geometry of the substrate by reducing its mechanical stiffness and, consequently, the stress accumulation during LPBF. To assess the feasibility of the strategy, a coupled thermo-mechanical finite element model, calibrated with the experimental evidence obtained from the LPBF metal deposition of a bridge-type structure, is used to predict the thermo-mechanical behavior of two T-shape AM parts built on (i) a typical solid substrate and (ii) a groove patterned substrate, respectively. The results show that several visible cracks appear at the interface between the build and the typical solid substrate due to stress concentration (up to 1600 MPa), while a crack-free component can be manufactured by adding grooves through the thickness of the substrate, without compromising the resulting microstructure and microhardness of the metallic materials with high crack sensitivity. The difference between the groove patterned substrate design with respect to the use of support structures used for printing cantilever structures is clarified to further justify the novelty of the proposed approach.
publishDate 2022
dc.date.none.fl_str_mv 2022
2022-11-01
2022
2022-09-20
dc.type.none.fl_str_mv journal article
http://purl.org/coar/resource_type/c_6501
VoR
http://purl.org/coar/version/c_970fb48d4fbd8a85
dc.type.openaire.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv https://hdl.handle.net/2117/373089
https://dx.doi.org/10.1016/j.addma.2022.103149
url https://hdl.handle.net/2117/373089
https://dx.doi.org/10.1016/j.addma.2022.103149
dc.language.none.fl_str_mv Inglés
eng
language_invalid_str_mv Inglés
language eng
dc.relation.none.fl_str_mv European Commission http://doi.org/10.13039/100010661 Horizon 2020 Framework Programme 872570 An Advanced Circular and Agile Manufacturing Ecosystem based on rapid reconfigurable manufacturing process and individualized consumer preferences
dc.rights.none.fl_str_mv open access
http://purl.org/coar/access_right/c_abf2
Attribution-NonCommercial-NoDerivatives 4.0 International
http://creativecommons.org/licenses/by-nc-nd/4.0/
dc.rights.openaire.fl_str_mv info:eu-repo/semantics/openAccess
rights_invalid_str_mv open access
http://purl.org/coar/access_right/c_abf2
Attribution-NonCommercial-NoDerivatives 4.0 International
http://creativecommons.org/licenses/by-nc-nd/4.0/
eu_rights_str_mv openAccess
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv Elsevier
publisher.none.fl_str_mv Elsevier
dc.source.none.fl_str_mv reponame:UPCommons. Portal del coneixement obert de la UPC
instname:Universitat Politècnica de Catalunya (UPC)
instname_str Universitat Politècnica de Catalunya (UPC)
reponame_str UPCommons. Portal del coneixement obert de la UPC
collection UPCommons. Portal del coneixement obert de la UPC
repository.name.fl_str_mv
repository.mail.fl_str_mv
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score 15,301603

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