Conventional manufacturing technologies, such as milling or casting, often reach their limits when complex geometries are involved. Additive manufacturing (AM) is a reasonable alternative for the fabrication of such parts. In particular, the powder bed fusion of metals using a laser beam (PBF-LB/M) has already been established in industrial production because it allows for the manufacturing of parts with high mechanical properties and a fine resolution. However, due to an uneven heat input during the process, the parts being manufactured are prone to thermally driven stress-induced cracking. We introduced an approach to predict regions within PBF-LB/M-manufactured parts that exhibit a high susceptibility to stress-induced fracture by means of numerical simulation. Previously identified and calibrated failure models for Inconel 718 were integrated into a PBF-LB/M process simulation, which uses the finite element method. Based on an implemented damage indicator, for which the failure models served as an input, critical locations due to the successive build-up of mechanical stresses and strains during layer-wise manufacturing were identified. The determined regions were experimentally validated by comparing the experimental results to the simulative predictions. An AM-adapted calibration approach allowed for a reliable prediction of crack-prone regions within PBF-LB/M-manufactured parts. An experimental method underestimated the susceptibility to failure, whereas a combined experimental and simulative approach overestimated it. The obtained results of this study contribute to the concept of first-time-right manufacturing as critical regions can be modified before the actual manufacturing process. The presented approach is also anticipated to be applicable to predicting crack formation between a solid part and its support structure.
Additive Manufacturing (AM) offers an alternative to conventional technologies for producing complex parts. Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) is widely used for its high mechanical properties. However, thermally-driven stress-induced cracking is a challenge due to the uneven heat input. This study proposes a simulation-based approach to predict vulnerable regions in PBF-LB/M parts. Failure models for Inconel 718 were integrated into a PBF-LB/M process simulation, enabling the identification of critical locations prone to stress-induced fracture. Experimental validations confirmed the accuracy of a classical and an AM-adapted calibration method in predicting crack-prone zones. This approach enhances first-time-right manufacturing by enabling preemptive modifications.
Access to the requested content is limited to institutions that have purchased or subscribe to SPIE eBooks.
You are receiving this notice because your organization may not have SPIE eBooks access.*
*Shibboleth/Open Athens users─please
sign in
to access your institution's subscriptions.
To obtain this item, you may purchase the complete book in print or electronic format on
SPIE.org.
INSTITUTIONAL Select your institution to access the SPIE Digital Library.
PERSONAL Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.