Determination of bi-dimensional normal residual stress distributions in metallic laser-based powder bed fusion parts

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

  • Joaquin Montero - , Bundeswehr University of Munich, Bundeswehr Research Institute for Materials, Fuels and Lubricants (Author)
  • Sebastian Weber - , Bundeswehr University of Munich, Bundeswehr Research Institute for Materials, Fuels and Lubricants (Author)
  • Matthias Bleckmann - , Bundeswehr Research Institute for Materials, Fuels and Lubricants (Author)
  • Kristin Paetzold - , Institute of Machine Elements and Machine Design, Chair of Virtual Product Development, TUD Dresden University of Technology (Author)
  • Eric A. Jägle - , Bundeswehr University of Munich (Author)

Abstract

Disadvantageous complex residual stress distributions are common in parts manufactured by laser-based powder bed fusion metals (PBF-LB/M). Thus, the residual stress state determination is essential for understanding the part's limitations. One residual stress measurement technique applicable to PBF-LB/M parts is the slitting method. This destructive technique allows through-thickness measurements and copes well with discontinuities in the material, yet is limited to one-dimensional stress profiles. Conversely, other stress measurement techniques, e.g. X-ray diffraction, are restricted to the part's surface. This article presents an inexpensive and straightforward stress determination approach that combines an implementation of the slitting method with X-ray diffraction measurements to create a continuous two-dimensional residual stress map along a part's cross-section. The approach was numerically validated using finite element models that simulate, on the one hand, the PBF-LB/M process and, on the other hand, the measuring process; further, it was experimentally tested in PBF-LB/M AlSi10Mg samples. The use of linear elastic fracture mechanics allowed a straightforward formulation of the approach, which enabled a high degree of automation. The accurate stress distribution results and the correlation with the simulations and previous studies demonstrate the approach's robustness and effectiveness for complex residual stress states determination in two dimensions.

Details

Original languageEnglish
Article number104437
JournalMechanics of Materials
Volume173
Publication statusPublished - Oct 2022
Peer-reviewedYes

Keywords

Keywords

  • Additive manufacturing, AlSi10Mg, Laser powder bed fusion, Residual stress, Slitting method, XRD