FEM Simulation of AlSi10Mg Artifact for Additive Manufacturing Process Calibration with Industrial-Computed Tomography Validation

Dimensional accuracy of selective laser melting (SLM) parts is one of manufacturers' major concerns. The additive manufacturing (AM) process is characterized by high-temperature gradients, consolidation, and thermal expansion, which induce residual stress on the part. These stresses are release...

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Bibliographic Details
Published in:Materials 2023-06, Vol.16 (13), p.4754
Main Authors: Patuelli, Cesare, Cestino, Enrico, Frulla, Giacomo, Valente, Federico, Servetti, Guido, Esposito, Fabio, Barbero, Luca
Format: Article
Language:English
Subjects:
3D printing
Additive manufacturing
Base plates
Calibration
Computed tomography
CT imaging
Design of experiments
Digital twins
Energy consumption
Finite element method
Geometric accuracy
High temperature
Laser beam melting
Lasers
Manufacturing
Methods
Morphology
Parameter identification
Plastic deformation
Process parameters
Residual stress
Simulation
Temperature
Thermal expansion
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Summary:Dimensional accuracy of selective laser melting (SLM) parts is one of manufacturers' major concerns. The additive manufacturing (AM) process is characterized by high-temperature gradients, consolidation, and thermal expansion, which induce residual stress on the part. These stresses are released by separating the part from the baseplate, leading to plastic deformation. Thermo-mechanical finite elements (FE) simulation can be adopted to determine the effect of process parameters on final geometrical accuracy and minimize non-compliant parts. In this research, a geometry for process parameter calibration is presented. The part has been manufactured and then analyzed with industrial computed tomography (iCT). An FE process simulation has been performed considering material removal during base plate separation, and the computed distortions have been compared with the results of the iCT, revealing good accordance between the final product and its digital twin.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma16134754