Journal
FINITE ELEMENTS IN ANALYSIS AND DESIGN
Volume 144, Issue -, Pages 30-37Publisher
ELSEVIER SCIENCE BV
DOI: 10.1016/j.finel.2018.02.004
Keywords
Super-Gaussian beam; Gaussian beam; Inverse-Gaussian beam; Ti-6Al-4V; Finite element analysis; Regression model; Residual stress
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Funding
- Boeing through the Center for Aerospace Manufacturing Technologies (CAMT)
- National Science Foundation Grant [CMMI-1547042]
- Intelligent Systems Center (ISC) at Missouri ST
- Div Of Civil, Mechanical, & Manufact Inn
- Directorate For Engineering [1625736] Funding Source: National Science Foundation
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Residual stress is a major problem in metal parts fabrication with the direct laser deposition (DLD) process due to severe temperature gradient around a molten pool. A three-dimensional finite element analysis (FEA) model with a simplified substrate clamping fixture modeling method is proposed, validated, and then implemented with a novel DLD heat input strategy in Ti-6Al-4V thin-wall structure fabrication, which was applied with multiple beam shapes, including a super-Gaussian beam, Gaussian beam, and inverse-Gaussian beam, to reduce residual stress in the final part. A regression model of the heat input and final part residual stress was obtained via a three-factor two-level full factorial design. An optimized heat input strategy was achieved based on response surface contour plots of the regression model.
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