In solid freeform fabrication (SFF) processes involving thermal deposition, thermal control of the process is critical for obtaining consistent build conditions and in limiting residual stress-induced warping of parts. In this research, a nondimensionalized plot (termed a process map) is developed from numerical models of laser-based material deposition of thin-walled structures. This process map quantifies the effects of changes in wall height, laser power, deposition speed and part preheating on melt pool length, which is an essential process parameter to control in order to obtain consistent build conditions. The principal application of this work is to the Laser Engineered Net Shaping (LENS) process under development at Sandia Laboratories; however, the general approach and a subset of the presented results are applicable to any SFF process involving a moving heat source. Procedures are detailed for using the process map to predict melt pool length and predictions are compared against experimentally measured melt pool lengths for stainless steel deposition in the LENS process.
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November 2001
Technical Papers
A Process Map for Consistent Build Conditions in the Solid Freeform Fabrication of Thin-Walled Structures
Aditad Vasinonta, Graduate Student,
Aditad Vasinonta, Graduate Student
Department of Mechanical Engineering, Carnegie Mellon University, 5000 Forbes Ave., Pittsburgh, PA 15213
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Jack L. Beuth, Associate Professor, Mem. ASME,
Jack L. Beuth, Associate Professor, Mem. ASME
Department of Mechanical Engineering, Carnegie Mellon University, 5000 Forbes Ave., Pittsburgh, PA 15213
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Michelle L. Griffith
Michelle L. Griffith
Mechanical Process Engineering, Sandia National Laboratories, P.O. Box 5800, MS 0958, Albuquerque, NM 87185
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Aditad Vasinonta, Graduate Student
Department of Mechanical Engineering, Carnegie Mellon University, 5000 Forbes Ave., Pittsburgh, PA 15213
Jack L. Beuth, Associate Professor, Mem. ASME
Department of Mechanical Engineering, Carnegie Mellon University, 5000 Forbes Ave., Pittsburgh, PA 15213
Michelle L. Griffith
Mechanical Process Engineering, Sandia National Laboratories, P.O. Box 5800, MS 0958, Albuquerque, NM 87185
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received Dec. 1999; revised Aug. 2000. Associate Editor: S. Kapoor.
J. Manuf. Sci. Eng. Nov 2001, 123(4): 615-622 (8 pages)
Published Online: August 1, 2000
Article history
Received:
December 1, 1999
Revised:
August 1, 2000
Citation
Vasinonta, A., Beuth, J. L., and Griffith, M. L. (August 1, 2000). "A Process Map for Consistent Build Conditions in the Solid Freeform Fabrication of Thin-Walled Structures ." ASME. J. Manuf. Sci. Eng. November 2001; 123(4): 615–622. https://doi.org/10.1115/1.1370497
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