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Meeting MS&T21: Materials Science & Technology
Symposium Additive Manufacturing: Large-Scale Metal Additive Manufacturing
Presentation Title Thermo-mechanical FEM Modeling and Machine Learning of Distortion on Overhang Structure in Laser Powder Bed Fusion Additive Manufacturing
Author(s) Xuesong Gao, Tyler High, Jesse Zhu, Wei Zhang, Hyeyun Song
On-Site Speaker (Planned) Xuesong Gao
Abstract Scope Net or near-net shape parts produced by additive manufacturing typically possess complex structures, e.g., overhang which is disposed to distortion problems. To address this, two kinds of thermo-mechanical models were developed. The first one used a lumped layer method where multiple layers were treated as a single “building block”. The distortion formation was calculated on the full scale part and the model exhibited high accuracy and efficiency. Another model was based on a moving heat source method where each pass and layer was simulated directly. The model geometry was scaled down by 10 times and most processing parameters were accounted for, such as power and scanning speed, etc. To validate these models, overhang structures were printed with in-situ temperature and distortion measurements. A machine learning program was developed to correlate the measured temperature distribution to the measured distortion. The roles of thermal stress on distortion formation were revealed.

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Machine Learning-based Geometric Compensation Method for Metal Additive Manufacturing
A Proposed Sustainable Framework to Assess Wire Arc Additive Manufacturing Efficiency in Processing of Different Mechanical Components
An Investigation of the Properties of Stamping Tool Inserts Manufactured Using a Novel Wire Deposition Additive Manufacturing Process
Effect of Inhomogeneous Grain Size on the Deformation Characteristics of Bimetallic Additively Manufactured Structure (BAMS) of 316L Austenitic Stainless Steel and Inconel 625
High Deposition Rate Wire Arc Directed Energy Deposition of 316L for Pressure Retaining Components in Nuclear Applications
Hybrid Metal Manufacturing of Large Freeform Geometries
Manufacturing Large Scale Metal Parts via AM – Current and Future Directions
Microstructure Modification of GMAW-DED 316L Stainless Steel
Moving Heat Source Process Simulation for Wire Arc Additive Manufacturing via a Mesh-free Method and GPU Computing
Novel Thermal Management Technique for Additive Manufacturing
Now On-Demand Only - Development of 3D Metal Printing for Toolmaking
Process Development for Laser Hot Wire Additive Manufacturing of Ti-6Al-4V
Thermo-mechanical FEM Modeling and Machine Learning of Distortion on Overhang Structure in Laser Powder Bed Fusion Additive Manufacturing
Towards Understanding Microstructure Evolution during Wire Arc Additive Manufacturing of Maraging 250 Thin-wall Parts
Wire Arc Processing of Stainless Steels; Microstructure and Properties
Wire + Arc Additive Manufacturing (WAAM) of Al0.1CoCrFeNi High-Entropy Alloy (HEA)

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