FEM Simulation of AlSi10Mg Artifact for Additive Manufacturing Process Calibration with Industrial-Computed Tomography Validation

Dimensional accuracy of selective laser melting (SLM) parts is one of manufacturers' major concerns. The additive manufacturing (AM) process is characterized by high-temperature gradients, consolidation, and thermal expansion, which induce residual stress on the part. These stresses are released by separating the part from the baseplate, leading to plastic deformation. Thermo-mechanical finite elements (FE) simulation can be adopted to determine the effect of process parameters on final geometrical accuracy and minimize non-compliant parts. In this research, a geometry for process parameter calibration is presented. The part has been manufactured and then analyzed with industrial computed tomography (iCT). An FE process simulation has been performed considering material removal during base plate separation, and the computed distortions have been compared with the results of the iCT, revealing good accordance between the final product and its digital twin.

Automated summary

Dimensional accuracy is a major concern in selective laser melting (SLM) parts manufacturing. This research presents a geometry for process parameter calibration and verifies it through industrial computed tomography (iCT) and thermo-mechanical finite element simulation. The results show good accordance between the simulated and actual products.