4th World Congress on Integrated Computational Materials Engineering (ICME 2017): Additive Manufacturing - I
Program Organizers: Paul Mason, Thermo-Calc Software Inc.; Michele Manuel, University of Florida; Alejandro Strachan, Purdue University; Ryan Glamm, Boeing Research and Technology; Georg J. Schmitz, Micress/Aachen; Amarendra Singh, IIT Kanpur; Charles Fisher, Naval Surface Warfare Center

Monday 10:30 AM
May 22, 2017
Room: Salon II, III
Location: Ann Arbor Marriott Ypsilanti at Eagle Crest

10:30 AM  
Prediction of Microstructure, Residual Stress, and Deformation in Laser Powder Bed Fusion Process: Yu-Ping Yang1; Mahdi Jamshidinia1; Paul Boulware1; 1EWI
    A transient thermal-metallurgical-mechanical analysis method has been developed to predict temperature, microstructure, hardness, stress, strain, and deformation for Laser powder bed fusion (L-PBF). The analysis method includes a pre-processing module, a powder deposition module, a thermal module, a metallurgical module, and a mechanical module. The pre-processing module is used to slice a solid geometry into layers and create laser heat lines for each layer based on a designed scan pattern. The power deposition module is used to model powder-to-solid transition by changing material properties based on the laser’s locations. The thermal module includes two heat-source models, a Goldak double-ellipsoidal model and a moving line heating model, which work with ABAQUS software to predict temperature by inputting laser power, travel speed, and a heat-line sequence. The metallurgical module is used to predict microstructure and hardness by inputting the predicted temperature history with the Goldak heat-source model. The mechanical module is used to predict stress and deformation by inputting the predicting temperature history with the line heat source model and modeling the melting effects. Microstructure and hardness of AISI 4140 steel built with L-PBF were predicted using the developed numerical modeling tool. Experimental measured hardness was used to validate the model prediction. It was found that tempering effect has to be modeled in order to predict the hardness correctly. Residual stress and deformation of Inconel 718 were predicted in a block sample built by L-PBF.