Efficient thermomechanical modelling of Laser Powder Bed Fusion additive manufacturing process with emphasis on parts residual stress fields

Harry O. Psihoyos; George N. Lampeas; Harry O. Psihoyos; George N. Lampeas

doi:10.3934/matersci.2022027

AIMS Materials Science

2022, Volume 9, Issue 3: 455-480. doi: 10.3934/matersci.2022027

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Efficient thermomechanical modelling of Laser Powder Bed Fusion additive manufacturing process with emphasis on parts residual stress fields

Harry O. Psihoyos ^{1
,
,},
George N. Lampeas ²

1.
ATHENA Research Center, Industrial Systems Institute, Patras Science Park Building Platani, Patras 26504, Greece
2.
Laboratory of Technology and Strength of Materials, Department of Mechanical Engineering & Aeronautics, University of Patras, Rion 26504, Western Greece, Greece

Received: 29 December 2021 Revised: 05 April 2022 Accepted: 14 April 2022 Published: 06 June 2022

Laser Powder Bed Fusion (LPBF) process is one of the advanced Additive Manufacturing (AM) processes, which is employed for the fabrication of complex metallic components. One of the major drawbacks of the LPBF is the development of residual stresses due to the high temperature gradients developed during the process thermal cycles. Reliable models for the prediction of residual strain and stress at part scale are required to support the LPBF process optimization. Due to the computational cost of the LPBF simulation, the current modelling methodology utilizes assumptions to make feasible the prediction of residual stresses at parts or component level. To this scope, a thermomechanical modelling approach for the simulation of LPBF process is presented with focus to residual stress and strain prediction. The modelling efficiency of the proposed approach was tested on a series on cases for which experimental data were available. The good comparison between the predicted and experimental data validated the modelling method. The efficiency of the thermomechanical modelling method is demonstrated by the reduced computational time required.
- additive manufacturing,
- Laser Powder Bed Fusion,
- Finite Element Method,
- thermomechanical modelling,
- residual stresses,
- distortions
Citation: Harry O. Psihoyos, George N. Lampeas. Efficient thermomechanical modelling of Laser Powder Bed Fusion additive manufacturing process with emphasis on parts residual stress fields[J]. AIMS Materials Science, 2022, 9(3): 455-480. doi: 10.3934/matersci.2022027

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Abstract

Laser Powder Bed Fusion (LPBF) process is one of the advanced Additive Manufacturing (AM) processes, which is employed for the fabrication of complex metallic components. One of the major drawbacks of the LPBF is the development of residual stresses due to the high temperature gradients developed during the process thermal cycles. Reliable models for the prediction of residual strain and stress at part scale are required to support the LPBF process optimization. Due to the computational cost of the LPBF simulation, the current modelling methodology utilizes assumptions to make feasible the prediction of residual stresses at parts or component level. To this scope, a thermomechanical modelling approach for the simulation of LPBF process is presented with focus to residual stress and strain prediction. The modelling efficiency of the proposed approach was tested on a series on cases for which experimental data were available. The good comparison between the predicted and experimental data validated the modelling method. The efficiency of the thermomechanical modelling method is demonstrated by the reduced computational time required.

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