Simulation-assisted prediction of residual stress-induced failure during powder bed fusion of metals using a laser beam

Hannes Panzer; Daniel Wolf; Michael F. Zaeh

doi:10.1117/12.3009497

13 March 2024 Simulation-assisted prediction of residual stress-induced failure during powder bed fusion of metals using a laser beam

Hannes Panzer, Daniel Wolf, Michael F. Zaeh

Author Affiliations +

Proceedings Volume PC12876, Laser 3D Manufacturing XI; PC128760B (2024) https://doi.org/10.1117/12.3009497
Event: SPIE LASE, 2024, San Francisco, California, United States

Abstract

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.

Conference Presentation

Citation Download Citation

Hannes Panzer, Daniel Wolf, and Michael F. Zaeh "Simulation-assisted prediction of residual stress-induced failure during powder bed fusion of metals using a laser beam", Proc. SPIE PC12876, Laser 3D Manufacturing XI, PC128760B (13 March 2024); https://doi.org/10.1117/12.3009497

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