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Understanding processing parameters affecting residual stress in selective laser melting of Inconel 718 through numerical modeling

Published online by Cambridge University Press:  06 February 2019

Jia Song Open the ORCID record for Jia Song [Opens in a new window] ,
Liang Zhang Open the ORCID record for Liang Zhang [Opens in a new window] ,
Wenheng Wu ,
Beibei He ,
Xiaoqing Ni ,
Jiongkai Xu ,
Guoliang Zhu ,
Qiyun Yang ,
Tao Wang  and
Lin Lu
Jia Song
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Liang Zhang*
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Wenheng Wu*
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Beibei He
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Xiaoqing Ni
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Jiongkai Xu
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Guoliang Zhu
Affiliation:
Shanghai Key Laboratory of Advanced High-temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Qiyun Yang
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Tao Wang
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
Lin Lu
Affiliation:
Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
*
a)Address all correspondence to these authors. e-mail: [email protected]
b)e-mail: [email protected]
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Abstract

In this study, a thermal–elastic–plastic finite element model is proposed to investigate the effect of volume energy density on the temperature field, molten pool size, and residual stress distribution in the selective laser melting (SLM) process of Inconel 718 alloy. A temperature-dependent thermal–mechanical property of materials is considered, as well as the properties conversion between powder layer and solidified alloy. Within the scope of the study parameters, the simulated molten pool size increases with increasing volume energy density and exhibits linear growth relationship, which are validated by the experimental results and show a good agreement. In addition, five scanning strategies are adopted to study the effect of these scanning strategies on the residual stress distribution in this research. The results show that the residual stress distribution of SLM Inconel 718 specimen largely depends on the scanning strategy. Finally, to reveal the mechanism of residual stress formation, the restraint bar model is used to further analyze the formation mechanism of residual stress during the SLM process.

Keywords

finite element modelvolume energy densityscanning strategyresidual stressInconel 718 alloy
Type
Article
Information
Journal of Materials Research , Volume 34 , Issue 8 , 29 April 2019 , pp. 1395 - 1404
Copyright
Copyright © Materials Research Society 2019 

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