Metal additive manufacturing of carbon steel with direct laser deposition: computer simulation
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FULL RESEARCH ARTICLE
Metal additive manufacturing of carbon steel with direct laser deposition: computer simulation Hamed Hosseinzadeh1 Received: 8 October 2019 / Accepted: 7 November 2020 © Springer Nature Switzerland AG 2020
Abstract Metal 3D printing technology is commercially available, but the quality of the printed product is still a challenging issue that needs to be improved. More research is needed to address the essential technical details of metal 3D printing. Important technical details are the alloy microstructure, imperfections like pores, distortion, surface roughness, and residual stress, which affect the mechanical properties of the printed sample like fatigue performance. This research has computationally studied metal 3D printing for carbon steel to address the parameters that affect the quality of the final product printed by direct laser deposition. Multiscale multiphysics computational algorithms were coding in Microsoft Visual Basics 2015 to simulate the thermal stress, deformation, and austenite grain topology. Energy and force equilibrium equations were numerically solved to simulate the thermal and mechanical history versus print’s adjustable parameters like scan speed, laser power, and rate of metal powders injection through the nozzle. The austenite grain size of steel is an important parameter that is directly related to the local thermal history. A stochastic computational code was developed to simulate grain morphology based on calculated thermal history. The simulation showed the dependence of von Mises stress and thermal history on the rate of metal powders injection, laser power, and scan speed. The simulation showed a rise in von Mises stress by increasing the scan speed and laser power. Print speed and laser power also change the local maximum temperature and the local alloy microstructure. The local austenite grain size increases by reducing scan speed in the heat-affected zone. The simulation showed that the microstructure of the printed part is not uniform, and different layers are distinctive. Keywords Metal 3D printing · Direct laser deposition · Computer simulation · Carbon steel · Metal additive manufacturing · Austenite grain size
1 Introduction Metal 3D printing processes are categorized by ASTM Standard F2792 as directed energy deposition (DED) and powder bed fusion (PBF). Other fabrication methods like binder jetting and ultrasonic additive manufacturing (AM) are also one of the metal 3D printing processes. In the methods that we melt the powder metals, metal 3D printers are using a heat source to melt materials locally or deposit the molten materials layer by layer [1]. The heat source is very similar to the welding process, i.e., electric arc, plasma, electron beams, and laser. Metal 3D printing is a kind of rapid prototyping, and it could be beneficial for * Hamed Hosseinzadeh [email protected] 1
Henry M. Rowan College of Engineering, Rowan University, 107 Gilbreth Parkway, Mullica Hill, NJ 08062, USA
producing non-structural applications for design purpo
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