Effects on the distortion of Inconel 718 components along a hybrid laser-based additive manufacturing process chain using laser powder bed fusion and laser metal deposition
Tóm tắt
The combination of laser powder bed fusion (LPBF), known for its geometrical freedom and accuracy, and the nozzle-based laser metal deposition process (LMD), known for its high build-up rates, has great potential to reduce the additive manufacturing times for large metallic parts. For the industrial application of the LPBF-LMD hybrid process chain, it is necessary to investigate the influence of the LMD process on the LPBF substrate. In addition, the build plate material also has a significant impact on the occurrence of distortion along the additive manufacturing process chain. In the literature, steel build plates are often used in laser-based additive manufacturing processes of Inconel 718, since a good metallurgical bonding can be assured whilst reducing costs in the production and restoration of the build plates. This paper examines the distortion caused by LMD material deposition and the influence of the build plate material along the hybrid additive manufacturing process chain. Twin cantilevers are manufactured by LPBF and an additional layer is subsequently deposited with LMD. The distortion is measured in the as-built condition as well as after heat treatment. The effect of different LMD hatch strategies on the distortion is determined. The experiments are conducted using the nickel-base alloy Inconel 718. The results show a significant influence of LMD path strategies on distortion, with shorter tool paths leading to less distortion. The remaining distortion after heat treatment is considerably dependent on the material of the build plate.
Tài liệu tham khảo
Wohlers T (2019) Wohlers report 2019: 3D printing and additive manufacturing state of the industry. WOHLERS Associates, Fort Collins
EOS GmbH—Electro Optical Systems, 2016. Material data sheet—FlexLine, EOS Nickel Alloy IN718, Manufacturer specification.
Buchbinder D, Schleifenbaum H, Heidrich S, Meiners W, Bültmann J (2011) High power selective laser melting (HP SLM) of aluminium parts. Phys Procedia 12:271–278
Bremen S, Buchbinder D, Meiners W, Wissenbach K (2011) Mit Selective Laser Melting auf dem Weg zur Serienproduktion? Laser Tech J 8(6):271–278
Kaierle S, Barroi A, Noelke C, Hermsdorf J, Overmeyer L, Haferkamp H (2012) Review on laser deposition welding: from micro to macro. Phys Procedia 39:336–345
Graf, B.; Schuch, M.; Kersting, R.; Gumenyuk, A.; Rethmeier, M.: Additive Process Chain using Selective Laser Melting and Laser Metal Deposition. Proc. of the Lasers in Manufacturing Conference (LIM) 2015.
Petrat T, Graf B, Gumenyuk A, Rethmeier M (2016) Laser metal deposition as repair technology for a gas turbine burner made of Inconel 718. Phys Procedia 83:761–768
Uhlmann, E.; Düchting, J.; Petrat, T.; Graf, B.; Rethmeier, M.: Heat treatment of SLM-LMD hybrid components. Proceedings of the Lasers in Manufacturing Conference (LIM) 2019.
Liu Q, Wang Y, Zheng H, Tang K, Ding L, Li H, Gong S (2016) Microstructure and mechanical properties of LMD-SLM hybrid forming Ti6Al4V alloy. Mater Sci Eng, A 660:24–33
Parimi LL, Attallah MM, Gebelin J, Reed RC (2012) Direct Laser Fabrication of Inconel‐718: effects on distortion and microstructure. In Superalloys 2012 Huron ES, Reed RC, Hardy MC, Mills MJ, Montero RE, Portella PD, Telesman J (eds). https://doi.org/10.1002/9781118516430.ch56
Nadammal N, Kromm A, Saliwan-Neumann R, Fahrabod L, Haberland C, Dolabella Portella P (2018) Influence of support configurations on the characteristics of selective laser melted Inconel 718. Jom 70:343–348
Wolff SJ, Gan Z, Lin S, Bennett JL, Yan W, Hyatt G, Ehmann KF, Wagner GJ, Liu WK, Cao J (2020) Experimentally validated predictions of thermal history and microhardness in laser-deposited Inconel 718 on carbon steel. Addit Manuf 27:540–551
Wang X, Chou K (2017) Electron backscatter diffraction analysis of Inconel 718 parts fabricated by selective laser melting additive manufacturing. Jom 69:402–408
Cheng Y, Xiao Z, Zhu H, Zeng X, Wang G (2019) Influence of substrate characteristics on residual stress of SLMed Inconel 718. Rapid Prototyp J 25(4):792–799
Gao M, Wang Z, Li X, Zeng X (2013) The effect of deposition patterns on the deformation of substrates during direct laser fabrication. J Eng Mater Technol 135:034502
Nazemi N, Urbanic RJ (2018) A numerical investigation for alternative toolpath deposition solutions for surface cladding of stainless steel P420 powder on AISI 1018 steel substrate. Int J Adv Manuf Technol 96:4123–4143
Salem M, Le Roux S, Hor A, Dour G (2020) A new insight on the analysis of residual stresses related distortions in selective laser melting of Ti-6Al-4V using the improved bridge curvature method. Addit Manuf 36:101586
Zongo F, Simoneau C, Timercan A, Tahan A, Brailovski V (2020) Geometric deviations of laser powder bed–fused AlSi10Mg components: numerical predictions versus experimental measurements. Int J Adv Manuf Technol 107:1411–1436
Barros R, Silva FJG, Gouveia RM, Saboori A, Marchese G, Biamino S, Salmi A, Atzeni E (2019) Laser powder bed fusion of Inconel 718: residual stress analysis before and after heat treatment. Metals 9:1290
El-Sari B, Biegler M, Graf B, Rethmeier M (2020) Distortion-based validation of the heat treatment simulation of directed energy deposition additive manufactured parts. Procedia CIRP 94:362–366
Fotovvati B, Asadi E (2019) Size effects on geometrical accuracy for additive manufacturing of Ti-6Al-4V ELI parts. Int J Adv Manuf Technol 104:2951–2959
Petrat T, Brunner-Schwer C, Graf B, Rethmeier M (2019) Microstructure of Inconel 718 parts with constant mass energy input manufactured with direct energy deposition. Procedia Manuf 36:256–266
VDI guideline 3405 Part 2.2, 2017. “Laser beam melting of metallic parts. Material data sheet nickel alloy material number 2.4668
Mugwagwa L, Dimitrov D, Matope S, Yadroitsev I (2019) Evaluation of the impact of scanning strategies on residual stresses in selective laser melting. Int J Adv Manuf Technol 102:2441–2450