Ingenieurwissenschaften und zugeordnete Tätigkeiten
Filtern
Erscheinungsjahr
Dokumenttyp
- Vortrag (41)
- Zeitschriftenartikel (32)
- Posterpräsentation (13)
- Beitrag zu einem Tagungsband (8)
- Dissertation (3)
- Beitrag zu einem Sammelband (1)
Schlagworte
- Residual stress (98) (entfernen)
Organisationseinheit der BAM
- 8 Zerstörungsfreie Prüfung (51)
- 8.5 Röntgenbildgebung (51)
- 9 Komponentensicherheit (42)
- 9.4 Integrität von Schweißverbindungen (39)
- 5 Werkstofftechnik (16)
- 9.2 Versuchsanlagen und Prüftechnik (11)
- 5.2 Metallische Hochtemperaturwerkstoffe (8)
- 5.1 Mikrostruktur Design und Degradation (7)
- 9.3 Schweißtechnische Fertigungsverfahren (6)
- 3 Gefahrgutumschließungen; Energiespeicher (5)
Paper des Monats
- ja (1)
Eingeladener Vortrag
- nein (41)
The contour scan strategies in laser powder bed fusion (LPBF) of Ti-6Al-4V were studied at the coupon level. These scan strategies determined the surface qualities and subsurface residual stresses. The correlations to these properties were identified for an optimization of the LPBF processing. The surface roughness and the residual stresses in build direction were linked: combining high laser power and high scan velocities with at least two contour lines substantially reduced the surface roughness, expressed by the arithmetic mean height, from values as high as 30 μm to 13 μm, while the residual stresses rose from ~340 to about 800 MPa. At this stress level, manufactured rocket fuel injector components evidenced macroscopic cracking. A scan strategy completing the contour region at 100 W and 1050 mm/s is recommended as a compromise between residual stresses (625 MPa) and surface quality (14.2 μm). The LPBF builds were monitored with an in-line twin-photodiode-based melt pool monitoring (MPM) system, which revealed a correlation between the intensity quotient I2/I1, the surface roughness, and the residual stresses. Thus, this MPM system can provide a predictive estimate of the surface quality of the samples and resulting residual stresses in the material generated during LPBF.
The paper deals with a numerical finite element simulation of the residual stress evolution in friction stir welding of 6 mm thick aluminum alloy AA2024-T3. The transient thermal field during the welding process was calculated with the commercial code COMSOL Multiphysics 5.0. Therefore, a thermal-pseudo-mechanical (TPM) heat source was implemented. A subsequent mechanical simulation was performed with varying hardening models for different welding speeds of 60 and 300 mm/min. The influence of softening of the material, which was due to hardening precipitation dissolution associated to the heating, was also investigated. Experiments in terms of thermocouple measurements as well as Vickers hardness and X-ray measurements of the residual stresses were conducted and compared to numerically obtained results. A qualitatively as well as quantitatively good agreement was found for different applied welding speeds.
While additive manufacturing (AM) is blossoming in nearly every industrial field, and the most different process are being used to produce components and materials, little attention is paid on the safety concerns around AM materials and processes.
Leveraging on our leading expertise in non-destructive testing (NDT) and materials characterization, we approach AM at BAM under two important viewpoints: first the on-line monitoring of the process and of the product, second the evolution of the (unstable) microstructure of AM materials under external loads.
These two subjects are the core of the two new-born internal projects ProMoAM and AGIL, respectively.
A detailed view of the goals and the organization of these two projects will be given, together with the expected output, and some preliminary results.
Having been introduced almost two decades ago, Additive Manufacturing (AM) of metals has become industrially viable for a large variety of applications, including aerospace, automotive and medicine. Powder bed techniques such as Selective Laser Melting (SLM) based on layer-by-layer deposition and laser melt enable numerous degrees of freedom for the geometrical design. Developing during the manufacturing process, residual stresses may limit the application of SLM parts by reducing the load bearing capacity as well as induce unwanted distortion depending on the boundary conditions specified in manufacturing.
The residual stress distribution in IN718 elongated prisms produced by SLM was studied non-destructively by means of neutron (bulk) and laboratory X-ray (surface) diffraction. The samples with different scanning strategies, i.e. hatching length, were measured in as-built condition (on a build plate) and after removal from the build plate.
While surface stress fields seem constant for AB condition, X-ray diffraction shows stress gradients along the hatch direction in the RE condition. The stress profiles correlate with the distortion maps obtained by tactile probe measurements.
Neutron diffraction shows bulk stress gradients for all principal components along the main sample directions. We correlate the observed stress patterns with the hatch length, i.e. with its effect on temperature gradients and heat flow. The bulk stress gradients partially disappear after removal from the baseplate.
Together with surface scan utilizing a coordinate-measuring machine (CMM), it is possible to link the stress release to the sample distortion.
We finally propose an explanation of those stress profiles based on the deposition strategy.
Influence of deposition hatch length on residual stress in selective laser melted Inconel 718
(2018)
The present study aims to evaluate the bulk residual stresses in SLM parts by using neutron diffraction measurements performed at E3 line -BER II neutron reactor- of Helmholtz-Zentrum für Materialien und Energie (HZB) Berlin. Together with microstructure characterization and distortion measurements, it is possible to describe the stress state throughout the whole sample. The sample was measured in as-build condition (on a build plate) and after releasing from the build plate. The used material is the nickel based superalloy 718. This alloy is widely used in aerospace and chemical industries due to its superior corrosion and heat resistant properties.
Obtained results indicated different residual stress states for each of the transversal, longitudinal and normal component. The normal and transversal component exhibits a rather compressive behavior while the longitudinal was tensile in the center part of the sample and became compressive towards the tip. As expected, the absolute values of all stress components decreased after releasing the sample from the building plate. A surface scan utilizing a coordinate-measuring machine (CMM) allowed us to present top surface distortion before and after releasing. The top surface showed a distortion around ±80µm after releasing. Microstructure evolution in the scanning-building cross-section is largely dominated by columnar grains. In addition, many small random orientated grains are prominent in the regions of a laser overlap during SLM.
In summary, for the sample of superalloy 718 manufactured by SLM, a small distortion occurred when removing the sample from the build plate whereby the residual stress state decreases. Moreover, the observed columnar grains in the building direction could give a reason for the lowest stress values in that normal direction. However, the most important parameter controlling the residual stresses is the temperature gradient. Hence, future investigations are planned for a different scan strategy to distribute the laser impact in a more homogenous manner.
The goal of reducing CO2 emissions in the automobile industry has led to the development of increasingly efficient lightweight material solutions that yield enhanced performance. In light of this goal, this current work involves the optimization of the pre-conditioning of novel, high toughness steel bearings without thermo-chemical treatment, with the aim of transferring the running-in phase into the final step of the mechanical finishing process. A case-hardened gear steel and two novel non-case-hardened steels were evaluated.
Additive Manufacturing (AM) by Selective Laser Melting (SLM) offers ample scope for producing geometrically complex parts as compared to the traditional subtractive manufacturing strategies. However, the residual stresses developed during the processing can reduce the load bearing capacity as well as induce unwanted distortion, limiting the application of SLM parts.
IN718 manufactured by SLM process can show high tensile residual stresses in the surface as high as the yield strength of the wrought alloy. On the other hand, residual stresses in the bulk Show considerably lower stress values, even in compression, indicating a stress re-distribution during deposition of the SLM layers.
Additive Manufacturing by Selective Laser Melting (SLM) offers ample scope for producing geometrically complex parts as compared to the traditional subtractive manufacturing strategies. However, the residual stresses (RS) developed during the processing can reduce the load bearing capacity as well as induce unwanted distortion, limiting the application of SLM parts. In the present work, residual stresses in additivly manufactured IN718 part were analised by means of neutron diffraction and synchrotron X-ray diffraction.
The residual stress distribution of IN718 parts produced by Selective Laser Melting (SLM) technique was studied by means of neutron diffraction.
Two deposition hatching lengths were considered in the fabrication. Both lateral (building direction) and top (finishing) near-surface regions were characterized. Measurements on samples in as-built condition and after release from the plate proved the presence of stress gradients both in-plane and along the building direction.
As-built samples presented in top region a longitudinal stress relief for large hatching, whereas small one showed tensile stresses around (200MPa) in the middle, evolving towards compression at the tip of the sample (down to -300MPa). Towards the lateral edge, longitudinal stresses shifted also to compression. The transverse stresses for large hatching were relief in the middle, whereas for small hatching shifted to compression at the edge. As for the normal component, this was more homogenous: stress-relief was proved for large hatching and, in contrast, was in compression (-200MPa) for small hatching. In the building direction (lateral region from base plate to top) of the sample with large hatching all stress components showed tensile values near the base plate (particularly high for normal component around 300MPa), decreasing towards compression to the top, where they were almost released.
After release, in the top region, the longitudinal stress component for small hatching showed high compressive stresses in the central part (down to -250MPa). In contrast, for large hatching a stress relief was found. In the transversal direction, this behavior was inverted: a small hatching released stresses more effectively, while a large hatching presented high tensile stresses (around 200MPa). As for the normal component (i.e., building direction), the sample with small hatching was found in compression, while that with large hatching was stress-released or slightly in tension (around 100MPa). In the lateral surface region, all components showed similar behavior: a small hatching promoted high compressive stresses along the building direction, whereas a large hatching showed small tensile values at the bottom, which balance towards the top region. There is an overall shift of stresses in 3 directions towards tension when compared with as-built condition for top region. In contrast, the lateral region is stress-relief or shifted towards compression after cutting from baseplate.
In conclusion, hatching length parameter strongly influenced the 3D distribution of residual stress in SLM produced parts.
The underlying cause of mechanical anisotropy in additively manufactured (AM) parts is not yet fully understood and has been attributed to several different factors like microstructural defects, residual stresses, melt pool boundaries, crystallographic and morphological textures. To better understand the main contributing factor to the mechanical anisotropy of AM stainless steel 316L, bulk specimens were fabricated via laser powder bed fusion (LPBF). Tensile specimens were machined from these AM bulk materials for three different inclinations: 0◦, 45◦, and 90◦ relative to the build plate. Dynamic Young’s modulus measurements and tensile tests were used to determine the mechanical anisotropy. Some tensile specimens were also subjected to residual stress measurement via neutron diffraction, porosity determination with X-ray micro-computed tomography (μCT), and texture analysis with electron backscatter diffraction (EBSD). These investigations revealed that the specimens exhibited near full density and the detected defects were spherical. Furthermore, the residual stresses in the loading direction were between −74 ± 24 MPa and 137 ± 20 MPa, and the EBSD measurements showed a preferential ⟨110⟩ orientation parallel to the build direction. A crystal plasticity model was used to analyze the elastic anisotropy and the anisotropic yield behavior of the AM specimens, and it was able to capture and predict the experimental behavior accurately. Overall, it was shown that the mechanical anisotropy of the tested specimens was mainly influenced by the crystallographic texture.
Independent from the interpass temperature residual stresses in longitudinal direction were lower than in transverse direction. This applies for the surface as well as for the bulk of the welds.
Residual stresses in the bulk were in general lower compared to stresses found on the surface.
Compressive residual stresses as a result of the martensite formation were formed in the bulk weld metal, only.
Independent from the LTT filler used high interpass temperatures were beneficial to reduce the stresses mainly in longitudinal direction.
Lower interpass temperatures tend to narrow the tensile zone in the weld metal but they also prevent the formation of compressive residual stresses.
Independent from the interpasstemperature residual stresses in longitudinal direction were lower than in transverse direction. This applies for the surface as well as for the bulk of the welds.
-Residual stresses in the bulk were in general lower compared to stresses found on the surface.
•Compressive residual stresses as a result of the martensite formation were formed in the bulk weld metal, only.
•Independent from the LTT filler used high interpasstemperatures were beneficial to reduce the stresses mainly in longitudinal direction.
•Lower interpasstemperatures tend to narrow the tensile zone in the weld metal but they also prevent the formation of compressive residual stresses.
Modifying the level of mostly detrimental welding residual stresses already during the welding process would be highly attractive as time- and cost-consuming post processing may be prevented. The nature of stress buildup during welding-associated cooling is highly affected by phase transformations. Up to now, it is not clear in which way this is applicable to real component welding exhibiting high shrinkage restraint and complex heat input. In this study, two different low transformation temperature (LTT) alloys have been investigated concerning the stress development in restrained multi-run butt welding in order to evaluate the potential of stress reduction. Pulsed gas metal arc welding (P-GMAW) welding was executed on a testing facility designed to simulate real lifelike restraint conditions of component weldments. The effect of reducedMS-temperatures and the heat control on the globally acting stresses was monitored by in-situ measurement of the reaction forces during welding fabrication. Additional local residual stress measurements allowed analyzing global as well as local loading of the welded construction. Although phase transformation has a significant influence on unloading the joint during each weld pass, the reaction stress upon cooling to room temperature seems to be determined mainly by the heat input. On the surface, low longitudinal residual stresses were observed in case of LTT whereas transverse residual stresses are less affected.
Additive manufacturing (AM) technologies are experiencing an exceedingly rapid growth, driven by their potential through layer wise deposition for transformational improvements of engineering design, leading to efficiency and performance improvements. Laser Powder Bed Fusion (LPBF) is an Additive Manufacturing (AM) method which permits the fabrication of complex structures that cannot otherwise be produced via conventional subtractive manufacturing methods. Nevertheless, the rapid cooling rates associated with this process results in the formation of significant and complex residual stress (RS) fields. A large body of both experimental and simulation research has been dedicated in recent years to the control and mitigation of RS in AM. In order to validate simulations with the end goal of being able to model the residual stress state in AM components and to devise strategies for their reduction during manufacturing, experimental methods need to be able to accurately determine 3D residual stresses fields in complex geometries. Several destructive and non-destructive methods can be used to analyze the RS state, the choice of which depends on the geometry and the information required. Diffraction-based methods using penetrating neutron and synchrotron X-rays at large scale facilities offer the possibility to non-destructively spatially resolve both surface and bulk residual stresses in complex components and track their changes following applied thermal or mechanical loads. This presentation will overview the success stories of using large scale facilities by the BAM for the characterization of residual stresses in additively manufactured metallic alloys. In particular, the study of the influence of process parameters on the residual stress state and the relaxation of these stresses through heat treatment will be presented. However there remains challenges to overcome particularly of the hypotheses underlying the experimental determination of residual stresses, which will be discussed.
Metal Additive manufacturing (AM) technologies such as Laser Powder Bed Fusion (LPBF) enable the fabrication of complex structures, giving rise to potential improvements in component and manufacturing efficiency. However, the processes are typically characterized by the generation of high magnitude residual stress (RS) which can have detrimental consequences for subsequent applications. Therefore, the characterization of these RS fields and the understanding of their formation and mitigation through optimized processing is crucial for the wider uptake of the technology. Due to the potential complex nature and high value of components manufactured by LPBF, it is important to have suitable characterisation methods which can determine the spatial variations of RS in a non-destructive manner. Neutron diffraction is considered to be the best suited for these requirements. However, the microstructures developed in the complex thermal cycles experience in the production can pose challenges to the ND method for RS analysis. The BAM has conducted significant research over the past years to overcome these obstacles, enabling higher confidence in the RS determined in LPBF materials by neutron diffraction. This contribution will overview some of these advancements made recently at European neutron sources including on Stress-Spec at FRM2/MLZ.
Residual stresses in Laser Beam Melting (LBM) – Critical Review and outlook of activities at BAM
(2019)
Additive manufacturing (AM) technologies have experienced an exceedingly rapid growth, which is coupled with the knowledge about the resulting material properties and performance. In particular, residual stress (RS) was soon recognized as an important issue in AM parts, such that parts are usually subjected to a post build-heat-treated. Significant effort has been spent on simulations of RS in AM, especially using finite element methods. As a consequence, the experimental determination of RS has thereby become increasingly important as a validation tool for simulations, as well as a method for assessing the influence of process parameters. In particular, diffraction methods, which are fundamentally non-destructive, offer enormous possibilities to gain knowledge on the residual stress state in real components, since synchrotron radiation and neutrons can penetrate even heavy metals up to several millimeters or centimeters, respectively. Indeed, significant progress has been achieved, in the understanding of the origins of the RS fields as a function of process parameters, as well as their stability under thermal and/or mechanical exposure.
In this paper, a few success stories will be outlined. It will be shown how the determination of RS in metallic parts (with the focus on those produced by laser powder bed fusion) has even revealed that process parameters that were previously considered unimportant (e.g. the position and orientation on the base plate) play a major role in the onset of residual stress accumulation.
However, while RS characterization is starting to be considered in the component design, deposition strategy (e.g. build plate temperature), and even in the definition of the relevant metric to assess the quality of a part, much is still to be investigates about the hypotheses underlying its experimental determination. Therefore, some aspects to be aware of, or even those which to date are unclear, will also be discussed. These include the determination of the stress-free reference and of the principal axes of stress. All of these aspects will lead towards a comprehensive understanding of the process-structure-performance relationships in AM materials and parts.
Residual stresses Analysis in Additively Manufactured alloys using neutron diffraction (L-PBF)
(2023)
An overview of recent progress at BAM of residual stress analysis in additively manufactured, in particular Laser Powder Bed Fusion of metallics materials, using neutron diffraction will be presented. This will cover important topics of the stress-free reference, the diffraction elastic moduli and principal stress determination.
An overview of the BAM funed Focus Area Materials Project "AGIL" will be presented. AGIL focussed on the stdiy of the ageing characteristics of additively manufactured austenitic stainless steel with a "powder to mechanical failure" Approach. Recent Highlights are presented and a perspective for future studies.