scholarly journals Measurement of the in-plane temperature field on the build plate during polymer extrusion additive manufacturing using infrared thermometry

2020 ◽  
Vol 92 ◽  
pp. 106866
Author(s):  
Hardikkumar Prajapati ◽  
Swapnil S. Salvi ◽  
Darshan Ravoori ◽  
Ankur Jain
Keyword(s):  
Temperature Field ◽  
Additive Manufacturing ◽  
Polymer Extrusion ◽  
Infrared Thermometry ◽  
Plane Temperature

Uncertainty Quantification in Metallic Additive Manufacturing Through Data-Driven Modelling Based on Multi-Scale Multi-Physics Models and Limited Experiment Data

2020 ◽  
Author(s):  
Zhuo Wang ◽  
Chen Jiang ◽  
Mark F. Horstemeyer ◽  
Zhen Hu ◽  
Lei Chen
Keyword(s):  
Temperature Field ◽  
Additive Manufacturing ◽  
Uncertainty Quantification ◽  
Surrogate Modeling ◽  
Data Driven ◽  
Modeling Framework ◽  
High Quality ◽  
Experimental Calibration ◽  
Multi Scale ◽  
Metallic Additive

Abstract One of significant challenges in the metallic additive manufacturing (AM) is the presence of many sources of uncertainty that leads to variability in microstructure and properties of AM parts. Consequently, it is extremely challenging to repeat the manufacturing of a high-quality product in mass production. A trial-and-error approach usually needs to be employed to attain a product with high quality. To achieve a comprehensive uncertainty quantification (UQ) study of AM processes, we present a physics-informed data-driven modeling framework, in which multi-level data-driven surrogate models are constructed based on extensive computational data obtained by multi-scale multi-physical AM models. It starts with computationally inexpensive metamodels, followed by experimental calibration of as-built metamodels and then efficient UQ analysis of AM process. For illustration purpose, this study specifically uses the thermal level of AM process as an example, by choosing the temperature field and melt pool as quantity of interest. We have clearly showed the surrogate modeling in the presence of high-dimensional response (e.g. temperature field) during AM process, and illustrated the parameter calibration and model correction of an as-built surrogate model for reliable uncertainty quantification. The experimental calibration especially takes advantage of the high-quality AM benchmark data from National Institute of Standards and Technology (NIST). This study demonstrates the potential of the proposed data-driven UQ framework for efficiently investigating uncertainty propagation from process parameters to material microstructures, and then to macro-level mechanical properties through a combination of advanced AM multi-physics simulations, data-driven surrogate modeling and experimental calibration.

Temperature distribution simulations during electron beam freeform fabrication process based on the fully threaded tree

2019 ◽  
Vol 25 (6) ◽  
pp. 989-997
Author(s):  
Yajun Yin ◽  
Wei Duan ◽  
Kai Wu ◽  
Yangdong Li ◽  
Jianxin Zhou ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Temperature Distribution ◽  
Design Methodology ◽  
Content Type ◽  
Freeform Fabrication ◽  
Simulation Based ◽  
Simulation Results

Purpose The purpose of this study is to simulate the temperature distribution during an electron beam freeform fabrication (EBF3) process based on a fully threaded tree (FTT) technique in various scales and to analyze the temperature variation with time in different regions of the part. Design/methodology/approach This study presented a revised model for the temperature simulation in the EBF3 process. The FTT technique was then adopted as an adaptive grid strategy in the simulation. Based on the simulation results, an analysis regarding the temperature distribution of a circular deposit and substrate was performed. Findings The FTT technique was successfully adopted in the simulation of the temperature field during the EBF3 process. The temperature bands and oscillating temperature curves appeared in the deposit and substrate. Originality/value The FTT technique was introduced into the numerical simulation of an additive manufacturing process. The efficiency of the process was improved, and the FTT technique was convenient for the 3D simulations and multi-pass deposits.

scholarly journals Low-cost Electromagnetic Heating Technology for Polymer Extrusion-based Additive Manufacturing

2016 ◽  
Author(s):  
William G. Carter ◽  
Orlando Rios ◽  
Ronald R. Akers ◽  
William A. Morrison
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Polymer Extrusion ◽  
Electromagnetic Heating ◽  
Heating Technology

scholarly journals Additive Manufacturing of Complex Components through 3D Plasma Metal Deposition—A Simulative Approach

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 574 ◽  
Author(s):  
Khaled Alaluss ◽  
Peter Mayr
Keyword(s):  
Temperature Field ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Field Distribution ◽  
Base Material ◽  
Metal Deposition ◽  
Temperature Fields ◽  
Experimental Investigations ◽  
Temperature Field Distribution ◽  
Elastic Plastic

This study examines simulative experimental investigations on the additive manufacturing of complex component geometries using 3D plasma metal deposition (3DPMD). Here, complex contour surfaces for a cross-rolling tool were produced from weld metals in multilayer technology through 3DPMD. As a consequence of the special features of 3DPMD with large-weld metal volumes, greatly differing properties between base material/deposited material and asymmetrical heat input, the resulting shrinkage, deformation and residual stresses are particularly critical. These lead to dimensional and form deviations as well as the formation of cracks, which has a negative influence on the quality of the plasma deposition-welded component structures. By means of the thermo-elastic-plastic simulation model, the temperature field distribution, deformation, and residual stresses occurring during additive 3DPMD of tool contours were predicted and analyzed. The temperature field distribution and its gradients were determined using the ellipsoid heat-source model for the 3DPMD process. On this basis, a coupled thermo-elastic-plastic structural–mechanical analysis was performed. Accordingly, the results achieved were used for the production of almost-net-shaped tool contour surfaces with predefined layer properties. The acquired simulation results of the temperature fields, deformation, and residual stress condition show good alignment with the experimental results.

Heat transfer in lattice structures during metal additive manufacturing: numerical exploration of temperature field evolution

2020 ◽  
Vol 26 (5) ◽  
pp. 911-928 ◽  
Author(s):  
David Downing ◽  
Martin Leary ◽  
Matthew McMillan ◽  
Ahmad Alghamdi ◽  
Milan Brandt
Keyword(s):  
Heat Transfer ◽  
Temperature Field ◽  
Additive Manufacturing ◽  
Future Research ◽  
Local Geometry ◽  
Lattice Structures ◽  
Content Type ◽  
Additional Heat ◽  
Metal Additive Manufacturing ◽  
Metal Additive

Purpose Metal additive manufacturing is an inherently thermal process, with intense localised heating and for sparse lattice structures, often rapid uneven cooling. Thermal effects influence manufactured geometry through residual stresses and may also result in non-isotropic material properties. This paper aims to increase understanding of the evolution of the temperature field during fabrication of lattice structures through numerical simulation. Design/methodology/approach This paper uses a reduced order numerical analysis based on “best-practice” compromise found in literature to explore design permutations for lattice structures and provide first-order insight into the effect of these design variables on the temperature field. Findings Instantaneous and peak temperatures are examined to discover trends at select lattice locations. Insights include the presence of vertical struts reduces overall lattice temperatures by providing additional heat transfer paths; at a given layer, the lower surface of an inclined strut experiences higher temperatures than the upper surface throughout the fabrication of the lattice; during fabrication of the lower layers of the lattice, isolated regions of material can experience significantly higher temperatures than adjacent regions. Research limitations/implications Due to the simplifying assumptions and multi-layer material additions, the findings are qualitative in nature. Future research should incorporate additional heat transfer mechanisms. Practical implications These findings point towards thermal differences within the lattice which may manifest as dimensional differences and microstructural changes in the built part. Originality/value The paper provides qualitative insights into the effect of local geometry and topology upon the evolution of temperature within lattice structures fabricated in metal additive manufacturing.

scholarly journals Simultaneous in Situ X-ray Scattering and Infrared Imaging of Polymer Extrusion in Additive Manufacturing

2019 ◽  
Vol 1 (6) ◽  
pp. 1559-1567 ◽  
Author(s):  
Yuval Shmueli ◽  
Jiaolong Jiang ◽  
Yuchen Zhou ◽  
Yuan Xue ◽  
Chung-Chueh Chang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Infrared Imaging ◽  
Polymer Extrusion ◽  
X Ray ◽  
X Ray Scattering ◽  
Ray Scattering

scholarly journals Numerical Modeling Design for the Hybrid Additive Manufacturing of Laser Directed Energy Deposition and Shot Peening Forming Fe–Cr–Ni–B–Si Alloy

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4877
Author(s):  
Xiaoyu Zhang ◽  
Dichen Li ◽  
Weijun Zhu
Keyword(s):  
Temperature Field ◽  
Additive Manufacturing ◽  
Tensile Stress ◽  
Compressive Stress ◽  
Shot Peening ◽  
Energy Deposition ◽  
Hybrid Process ◽  
Forming Process ◽  
Directed Energy Deposition ◽  
Directed Energy

Hybrid additive manufacturing is of great significance to make up for the deficiency of the metal forming process; it has been one of the main trends of additive manufacturing in recent years. The hybrid process of laser directed energy deposition (laser DED) and shot peening is a new technology combining the principles of surface strengthening and additive manufacturing, whose difficulty is to reduce the interaction between the two processes. In this paper, a new model with a discrete phase and fluid–solid interaction method is established, and the location of the shot peening point in the hybrid process is optimized. The distributions of the temperature field and powder trajectory were researched and experiments were carried out with the optimized parameters to verify simulation results. It was found that the temperature field and the powder trajectory partly change, and the optimized injection point is located in the stress relaxation zone of the material. The densities and surface residual stresses of samples were improved, and the density increased by 8.83%. The surface stress changed from tensile stress to compressive stress, and the introduced compressive stress by shot peening was 2.26 times the tensile stress produced by laser directed energy deposition.

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