Journal
ADDITIVE MANUFACTURING
Volume 60, Issue -, Pages -Publisher
ELSEVIER
DOI: 10.1016/j.addma.2022.103263
Keywords
Directed energy deposition; Laser powder bed fusion; Laser cladding; Heat accumulation; Residual temperature; Temperature evolution
Funding
- Alexander von Humboldt Foundation
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The accumulation of heat during additive manufacturing processes can result in shape deviations and inhomogeneous properties of the parts. This research provides an analytical description of the heat accumulation effect and proposes optimization strategies to reduce heat accumulation and increase productivity.
The flexibility of additive manufacturing processes results from the principle of subsequently adding small amounts of material in individual layers or beads on top of each other. The periodic input of energy required to melt the material can lead to an accumulation of heat, which increases the temperature of the part and changes the local temperature distribution in the melt pool. This heat accumulation results in local shape deviations of the part and can lead to inhomogeneous solidification conditions coinciding with inhomogeneous grain structures and potentially inhomogeneous mechanical properties or build failures. To produce high quality parts with homogeneous properties and to reduce unproductive dwell times, a comprehensive knowledge of the heat accumulation phenomena is required. The present work considers an explicit analytical description of the heat accumulation effect, which allows for a mathematical analysis of the influence of all contributing process pa-rameters on the temperature increase of the part. The analytical equations were derived from simplified heat conduction equations and validated by comparison with temperature measurements from literature. The calculated temperature increase shows a good agreement with measurements observed during additive manufacturing of different materials and alloys in case of cladding or building volumes with direct energy deposition (DED) and laser powder bed fusion (LPBF). Finally, the obtained analytical solution is used to derive optimization strategies aiming to reduce heat accumulation while simultaneously increasing productivity.
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