About this Abstract |
Meeting |
2025 TMS Annual Meeting & Exhibition
|
Symposium
|
Additive Manufacturing Modeling, Simulation and Machine Learning
|
Presentation Title |
Thermo-Mechanical Modeling and Validation of Residual Stress During Metal Laser Powder Bed Fusion and Post-Build Stress Relief Heat Treatment Processes |
Author(s) |
Prataprao Patil, Alon Mazor, Bartlomiej Pielacha, Yan Gao |
On-Site Speaker (Planned) |
Prataprao Patil |
Abstract Scope |
Metal laser powder bed fusion (L-PBF) is an innovative technology for manufacturing intricate shapes with short lead times. However, the repetitive heating and cooling cycles during printing induce distortion and residual stress, potentially leading to cracks and build failures. This study simulates both the build and post-build processes using Ansys through finite element-based thermo-mechanical simulations. The thermal simulation addresses temperature gradients during the build, and the resulting thermal history informs elastoplastic mechanical analysis for estimating residual stress and distortion. The stress-relieving process is simulated as a continuation, incorporating initial distortions and built-in stresses. The novelty of this work lies in integrating build and post-build simulations, validated against synchrotron X-ray measurements, which show excellent correlation. This comprehensive modeling approach allows for more accurate residual stress and distortion predictions throughout the L-PBF manufacturing process. |
Proceedings Inclusion? |
Planned: |
Keywords |
Additive Manufacturing, Modeling and Simulation, Computational Materials Science & Engineering |