Thermomechanical models are presented for the building of thin-walled structures by laser-based solid freeform fabrication (SFF) processes. Thermal simulations are used to develop quasi-non-dimensional plots (termed process maps) that quantify the effects of changes in wall height, laser power, deposition speed, and part preheating on thermal gradients, with the goal of limiting residual stresses in manufactured components. Mechanical simulations are used to demonstrate the link between thermal gradients and maximum final residual stresses. The approach taken is analogous to that taken in previous research by the authors in developing process maps for melt pool length, for maintaining an optimal melt pool size during component fabrication. Process maps are tailored for application to the laser engineered net shaping process; however, the general approach, insights, and conclusions are applicable to most SFF processes involving a moving heat source, and to other laser-based fusion processes. Results from the residual stress simulations identify two mechanisms for reducing residual stresses and quantify maximum stress reductions achievable through manipulation of all process variables. Results from thermal gradient and melt pool length process maps are used to identify a manufacturing strategy for obtaining a consistent melt pool size while limiting residual stress in a thin-walled part.
Skip Nav Destination
e-mail: beuth@andrew.cmu.edu
Article navigation
February 2007
Technical Papers
Process Maps for Predicting Residual Stress and Melt Pool Size in the Laser-Based Fabrication of Thin-Walled Structures
Aditad Vasinonta,
Aditad Vasinonta
Graduate Student
Department of Mechanical Engineering,
Carnegie Mellon University
, 5000 Forbes Avenue, Pittsburgh, PA 15213
Search for other works by this author on:
Jack L. Beuth,
Jack L. Beuth
Professor
Mem. ASME
Department of Mechanical Engineering,
e-mail: beuth@andrew.cmu.edu
Carnegie Mellon University
, 5000 Forbes Avenue, Pittsburgh, PA 15213
Search for other works by this author on:
Michelle Griffith
Michelle Griffith
Mechanical Process Engineering,
Sandia National Laboratories
, P. O. Box 5800, MS 0958, Albuquerque, NM 87185
Search for other works by this author on:
Aditad Vasinonta
Graduate Student
Department of Mechanical Engineering,
Carnegie Mellon University
, 5000 Forbes Avenue, Pittsburgh, PA 15213
Jack L. Beuth
Professor
Mem. ASME
Department of Mechanical Engineering,
Carnegie Mellon University
, 5000 Forbes Avenue, Pittsburgh, PA 15213e-mail: beuth@andrew.cmu.edu
Michelle Griffith
Mechanical Process Engineering,
Sandia National Laboratories
, P. O. Box 5800, MS 0958, Albuquerque, NM 87185J. Manuf. Sci. Eng. Feb 2007, 129(1): 101-109 (9 pages)
Published Online: March 31, 2006
Article history
Received:
August 19, 2004
Revised:
March 31, 2006
Citation
Vasinonta, A., Beuth, J. L., and Griffith, M. (March 31, 2006). "Process Maps for Predicting Residual Stress and Melt Pool Size in the Laser-Based Fabrication of Thin-Walled Structures." ASME. J. Manuf. Sci. Eng. February 2007; 129(1): 101–109. https://doi.org/10.1115/1.2335852
Download citation file:
Get Email Alerts
Related Articles
A Process Map for Consistent Build Conditions in the Solid Freeform Fabrication of Thin-Walled Structures
J. Manuf. Sci. Eng (November,2001)
Experimental Validation of Analytical Solutions for Vertical Flat Plate of Finite Thickness Under Natural-Convection Cooling
J. Heat Transfer (March,2008)
Modeling of Crack Propagation in Thin-Walled Structures Using a Cohesive Model for Shell Elements
J. Appl. Mech (November,2006)
Statistical Properties of Residual Stresses and Intergranular Fracture in Ceramic Materials
J. Appl. Mech (March,1993)
Related Proceedings Papers
Related Chapters
Research on Deformation of Aerospace Thin-Walled Structure Part in NC Machining Process
International Conference on Instrumentation, Measurement, Circuits and Systems (ICIMCS 2011)
Introduction
Marketing of Engineering Consultancy Services: A Global Perspective
Industrially-Relevant Multiscale Modeling of Hydrogen Assisted Degradation
International Hydrogen Conference (IHC 2012): Hydrogen-Materials Interactions