Working Paper Article Version 1 This version is not peer-reviewed

Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components made by Laser Metal Deposition with Wire

Version 1 : Received: 7 November 2019 / Approved: 10 November 2019 / Online: 10 November 2019 (09:04:24 CET)

How to cite: Lee, Y.; Bandari, Y.; Nandwana, P.; Gibson, B.; Richardson, B.; Simunovic, S. Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components made by Laser Metal Deposition with Wire. Preprints 2019, 2019110098 Lee, Y.; Bandari, Y.; Nandwana, P.; Gibson, B.; Richardson, B.; Simunovic, S. Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components made by Laser Metal Deposition with Wire. Preprints 2019, 2019110098

Abstract

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency, and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180⁰ rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.

Subject Areas

large-scale additive manufacturing; interlayer cooling time; tool path optimization; part deformation; Ti-6Al-4V

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