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Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion.

ABSTRACT: An efficient thermal-structural numerical solver for Additive Manufacturing has been developed based on a modified Lagrangian approach to solve the energy conservation equations in differential form. The heat transfer is modeled using the finite difference method applied to a deforming Lagrangian mesh. The structural solver has been enhanced with the proposed effective quasi-elastic differential approach for modeling the elastoplastic behavior of materials. The algorithm is relatively simple to implement yet is highly effective. The solver can predict shape deformations of metal parts printed using the laser powder bed fusion technique. The second key capability of the solver is the auto-compensation of distortions of 3D-printed parts by proposing a corrected geometry of a surface to be printed, in order to ensure minimal deviation of the actual printed part from the desired one, even under non-optimal operating conditions or for complex shapes. All the simulation results have been verified in real-life experiments for 3D parts of sizes ranging from 10 to 15 mm up to 40 mm.

SUBMITTER: Tsivilskiy I

PROVIDER: S-EPMC10579232 | biostudies-literature | 2023 Oct

REPOSITORIES: biostudies-literature

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Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion.

Tsivilskiy Ilya I Shishkovsky Igor I

Scientific reports 20231016 1

An efficient thermal-structural numerical solver for Additive Manufacturing has been developed based on a modified Lagrangian approach to solve the energy conservation equations in differential form. The heat transfer is modeled using the finite difference method applied to a deforming Lagrangian mesh. The structural solver has been enhanced with the proposed effective quasi-elastic differential approach for modeling the elastoplastic behavior of materials. The algorithm is relatively simple to ...[more]

PMID: 37845229

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Project description:We describe here the relationship between grain structure, deformation mechanism and fracture characteristics in an austenitic stainless steel. This was accomplished using the novel concept of phase reversion that enabled a wide range of grain size from nanograined/ultrafine grained (NG/UFG) to coarse-grained (CG) regime to be obtained in a single material through change in temperature-time annealing sequence. In the NG/UFG structure, a marked increase in abundance of stacking faults (SFs) and twin density with strain was observed that led to a decrease in the average spacing between adjacent SFs, thus converting stacking faults into twins. Twinning in NG/UFG structure involved partial dislocations and their interaction with the grain boundaries, including SF overlapping and the coordinated nucleation of partial dislocations from the grain boundaries. The plastic zone in the NG/UFG structure resembled a network knitted by the intersecting twins and SFs. With SFE ~30 mJ/m2, the minimum stress for twin nucleation was ~250?MPa for the experiment steel and the corresponding optimal grain size (dop) wa ~120?nm. In contrast, in the CG structure, strain induced martensite formation was the deformation mechanism. The difference in the deformation mechanism led to a clear distinction in the fracture behavior from striated fracture in high strength-high ductility NG/UFG alloy to microvoid coalescence in the low strength-high ductility CG counterpart. The underlying reason for the change in fracture behavior was consistent with change in deformation mechanism from nanoscale twinning in NG/UFG alloy to strain-induced martensite in the CG alloy, which is related to change in the stability of austenite with grain size. An analysis of critical shear stress required to initiate twinning partial dislocations in comparison to that required to nucleate shear bands is presented. The appearance of striated fracture in the NG/UFG alloy suggests a quasi-static step wise crack growth process.

Dataset Information

Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion.

Publications

Thermal-structural hybrid Lagrangian solver and numerical simulation-based correction of shape deformation of stainless-steel parts produced by laser powder bed fusion.

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