The Investigation of Temperature Distribution and Thermal Problems in DMLS Additive Manufacturing

Year 2019, Volume: 7 Issue: 1, 79 - 94, 15.01.2019

Mevlüt Yunus Kayacan Nihat Yılmaz

https://doi.org/10.21541/apjes.408921

Abstract

In this study,
studies on unstable temperature distribution, one of the biggest problems of
joint manufacturing, have been evaluated. Heterogeneous temperature
distributions, residual stresses and dimensional changes were investigated,
which are the most important factors in manufacturing faults. The problems that
arise during manufacturing in different types of metal materials have been
evaluated in terms of direct metal laser sintering (DMLS) and manufacturing
method. The faulty effect of manufacturing parameters has been investigated.
Different approaches on pre-manufacturing temperature and error estimation were
also discussed with finite element analysis. As a result, what needs to be done
to rectify the mistakes is revealed in the light of the available information.

Keywords

DMLS, sintering, parameter, thermal effect, residual stresses, powder bed fusion

DMLS İle Eklemeli İmalatta Dengesiz Sıcaklık Dağılımı Ve Parçaya Etkilerinin Araştırılması

Abstract

Bu Çalışma, eklemeli imalatın en
önemli problemlerinden bir tanesi olan dengesiz sıcaklık dağılımı üzerine
yapılan çalışmaların araştırılmasını konu almaktadır. İmalat esnasında meydana
gelen hatalara etki eden önemli parametrelerden olan heterojen sıcaklık
dağılımı, kalıntı gerilemeler ve boyutsal değişimler araştırılmıştır. Farklı
tip metal malzemelerin doğrudan metal lazer sinterleme (DMLS) yöntemi ile
imalatı esnasında parça üzerinde meydana gelen sorunlar incelenmiştir. İmalat
parametrelerinin meydana gelen hatalara olan etkisi incelenmiştir. Sonlu
elemanlar analizleri ile imalat öncesi sıcaklık ve hata tahmini konusunda
gerçekleştirilmiş farklı yaklaşımlar da ele alınmıştır. Sonuç olarak hataların
giderilmesi konusunda yapılması gerekenler, mevcut bilgiler ışığında ortaya
konulmuştur.

Keywords

DMLS, sinterleme, parametre, termal etki, kalıntı gerilmeler, toz yatak eklemeli imalat

References

• W. J. Sames, F. A. List, S. Pannala, R. R. Dehoff, Ve S. S. Babu, “The Metallurgy And Processing Science Of Metal Additive Manufacturing”, Int. Mater. Rev., C. 61, Sayı 5, Ss. 315–360, 2016.
• C. Körner, “Additive Manufacturing Of Metallic Components By Selective Electron Beam Melting - A Review”, Int. Mater. Rev., C. 61, Sayı 5, Ss. 361–377, 2016.
• D. D. Gu, W. Meiners, K. Wissenbach, Ve R. Poprawe, “Laser Additive Manufacturing Of Metallic Components: Materials, Processes And Mechanisms”, Int. Mater. Rev., C. 57, Sayı 3, Ss. 133–164, 2012.
• D. Herzog, V. Seyda, E. Wycisk, Ve C. Emmelmann, “Additive Manufacturing Of Metals”, Acta Mater., C. 117, Ss. 371–392, Eyl. 2016.
• T. Debroy, H. L. Wei, J. S. Zuback, T. Mukherjee, J. W. Elmer, J. O. Milewski, A. M. Beese, A. Wilson-Heid, A. De, Ve W. Zhang, “Additive Manufacturing Of Metallic Components – Process, Structure And Properties”, Prog. Mater. Sci., C. 92, Ss. 112–224, Mar. 2018.
• K. V. Wong Ve A. Hernandez, “A Review Of Additive Manufacturing”, Isrn Mech. Eng., C. 2012, Ss. 1–10, 2012.
• S. K. Everton, M. Hirsch, P. Stravroulakis, R. K. Leach, Ve A. T. Clare, “Review Of İn-Situ Process Monitoring And İn-Situ Metrology For Metal Additive Manufacturing”, Mater. Des., C. 95, Ss. 431–445, 2016.
• W. E. Frazier, “Metal Additive Manufacturing: A Review”, J. Mater. Eng. Perform., C. 23, Sayı 6, Ss. 1917–1928, 2014.
• M. Y. Kayacan, S. Sayer,“Ürün Geliştirme Sürecinde Hızlı Prototip Uygulamaları”, Plast. Derg., C. 125, Ss. 122–130, 2014.
• Astm International, F2792-12a - Standard Terminology For Additive Manufacturing Technologies. 2013.
• D. Manfredi, F. Calignano, E. P. Ambrosio, M. Krishnan, R. Canali, S. Biamino, M. Pavese, E. Atzeni, L. Luliano, P. Fino, Ve C. Badini, “Direct Metal Laser Sintering: An Additive Manufacturing Technology Ready To Produce Lightweight Structural Parts For Robotic Applications”, Metall. Ital., C. 105, Sayı 10, Ss. 15–24, 2013.
• Wikipedia, 2014. [Çevrimiçi]. Available At: Https://En.Wikipedia.Org/Wiki/Selective_Laser_Sintering.
• Additively.Com, 2018 [Çevrimiçi]. Available At: Https://Www.Additively.Com/En/Learn-About/Laser-Melting.
• M. Yan, S. D. Luo, G. B. Schaffer, Ve M. Qian, “Impurity (Fe, Cl, And P)-İnduced Grain Boundary And Secondary Phases İn Commercially Pure Titanium (Cp-Ti)”, Metall. Mater. Trans. A Phys. Metall. Mater. Sci., C. 44, Sayı 8, Ss. 3961–3969, 2013.
• M. Yan, M. S. Dargusch, C. Kong, J. A. Kimpton, S. Kohara, M. Brandt, Ve M. Qian, “In Situ Synchrotron Radiation Study Of Tih2-6al-4v And Ti-6al-4v: Accelerated Alloying And Phase Transformation, And Formation Of An Oxygen-Enriched Ti4fe2o Phase İn Tih2-6al-4v”, Metall. Mater. Trans. A Phys. Metall. Mater. Sci., C. 46, Sayı 1, Ss. 41–45, 2015.
• M. Yan, S. D. Luo, G. B. Schaffer, Ve M. Qian, “Tem And Xrd Characterisation Of Commercially Pure ??-Ti Made By Powder Metallurgy And Casting”, Mater. Lett., C. 72, Ss. 64–67, 2012.
• M. Yan, M. Qian, C. Kong, Ve M. S. Dargusch, “Impacts Of Trace Carbon On The Microstructure Of As-Sintered Biomedical Ti-15mo Alloy And Reassessment Of The Maximum Carbon Limit”, Acta Biomater., C. 10, Sayı 2, Ss. 1014–1023, 2014.
• K. U. Kainer, “High Temperature Ceramic Matrix Composites”, 2006.
• M. Qian, Y. F. Yang, S. D. Luo, Ve H. P. Tang, 12. Elsevier Inc., 2015.
• K. Crosby, “Titanium-6aluminum-4vanadium For Functionally Graded Orthopedic Implant Applications”, Univ. Connect., 2013.
• I. Gibson, D. W. Rosen, Ve B. Stucker, “Additive Manufacturing Technologies”, Vasa, Sayı December, 2010.
• J. Wroe, Introductıon To Additive Manufacturing Technology, 1st Baskı. Shrewsburry: Association, European Powder Metallurgy, 2012.
• A. Simchi Ve H. Pohl, “Effects Of Laser Sintering Processing Parameters On The Microstructure And Densification Of İron Powder”, Mater. Sci. Eng. A, C. 359, Sayı 1–2, Ss. 119–128, 2003.
• J. Delgado, J. Ciurana, Ve C. A. Rodríguez, “Influence Of Process Parameters On Part Quality And Mechanical Properties For Dmls And Slm With İron-Based Materials”, Int. J. Adv. Manuf. Technol., C. 60, Sayı 5–8, Ss. 601–610, 2012.
• F. Calignano, D. Manfredi, E. P. Ambrosio, L. Iuliano, Ve P. Fino, “Influence Of Process Parameters On Surface Roughness Of Aluminum Parts Produced By Dmls”, Int. J. Adv. Manuf. Technol., C. 67, Sayı 9–12, Ss. 2743–2751, 2013.
• H. Pohl, A. Simchi, M. Issa, Ve H. C. Dias, “Thermal Stresses İn Direct Metal Laser Sintering”, Proc. Sff Symp., Ss. 366–372, 2001.
• I. Shishkovsky, “Stress-Strain Analysis Of Porous Scaffolds Made From Titanium Alloys Synthesized Via Sls Method”, Appl. Surf. Sci., C. 255, Sayı 24, Ss. 9902–9905, 2009.
• H. Exner, P. Regenfuss, L. Hartwig, S. Klötzer, Ve R. Ebert, “Selective Laser Micro Sintering With A Novel Process”, Proc. Spıe, C. 5063, Ss. 145–151, 2003.
• S. Caro, D. Chablat, R. Ur-Rehman, P. Wenger, Ve A. Bernard, “Global Product Development”, Ss. 373–383, 2011.
• L. S. Bertol, W. K. Júnior, F. P. Da Silva, Ve C. Aumund-Kopp, “Medical Design: Direct Metal Laser Sintering Of Ti-6al-4v”, Mater. Des., C. 31, Sayı 8, Ss. 3982–3988, 2010.
• R. Paul, “Modeling And Optimization Of Powder Based Additive Manufacturing (Am) Processes”, 2013.
• F. Xie, X. He, S. Cao, Ve X. Qu, “Structural And Mechanical Characteristics Of Porous 316l Stainless Steel Fabricated By İndirect Selective Laser Sintering”, J. Mater. Process. Technol., C. 213, Sayı 6, Ss. 838–843, 2013.
• C. Aumund-Kopp Ve F. Petzoldt, “Laser Sintering Of Parts With Complex İnternal Structures”, Proc. 2008 World Congr. Powder Metall. Part. Mater., C. 1, Sayı 3, Ss. 385–397, 2008.
• T. Hayashi, K. Maekawa, M. Tamura, Ve K. Hanyu, “Selective Laser Sintering Method Using Titanium Powder Sheet Toward Fabrication Of Porous Bone Substitutes”, Jsme Int. J. Ser. A, C. 48, Sayı 4, Ss. 369–375, 2005.
• L. Ventola, F. Robotti, M. Dialameh, F. Calignano, D. Manfredi, E. Chiavazzo, Ve P. Asinari, “Rough Surfaces With Enhanced Heat Transfer For Electronics Cooling By Direct Metal Laser Sintering”, Int. J. Heat Mass Transf., C. 75, Ss. 58–74, 2014.
• Y. Ning, “Process Parameter Optimization For Direct Metal Laser Sintering ( Dmls )”, S. 167, 2005.
• M. H. Farshidianfar, A. Khajepour, Ve A. P. Gerlich, “Effect Of Real-Time Cooling Rate On Microstructure İn Laser Additive Manufacturing”, J. Mater. Process. Technol., C. 231, Ss. 468–478, 2016.
• Y. Ningy, J. Y. H. Fuhy, Y. S. Wongy, Ve H. T. Lohy, “An İntelligent Parameter Selection System For The Direct Metal Laser Sintering Process”, Int. J. Prod. Res, C. 42, Sayı 1, Ss. 183–199, 2004.
• Y. Ning, Y. S. Wong, J. Y. H. Fuh, Ve H. T. Loh, “An Approach To Minimize Build Errors İn Direct Metal Laser Sintering”, Ieee Trans. Autom. Sci. Eng., C. 3, Sayı 1, Ss. 73–80, 2006.
• S. Merkt, C. Hinke, J. Bultmann, M. Brandt, Ve M. Xie, “The Mechanical Response Of Tial6v4 Lattice Structures Manufactured By Slm İn Quasi Static And Dynamic Compression Tests”, C. 17006, Ss. 3–10, 2015.
• J. Parthasarathy, B. Starly, Ve S. Raman, “A Design For The Additive Manufacture Of Functionally Graded Porous Structures With Tailored Mechanical Properties For Biomedical Applications”, J. Manuf. Process., C. 13, Sayı 2, Ss. 160–170, 2011.
• C. Yan, L. Hao, A. Hussein, P. Young, J. Huang, Ve W. Zhu, “Microstructure And Mechanical Properties Of Aluminium Alloy Cellular Lattice Structures Manufactured By Direct Metal Laser Sintering”, Mater. Sci. Eng. A, C. 628, Ss. 238–246, 2015.
• M. Yan Ve P. Yu, “An Overview Of Densification, Microstructure And Mechanical Property Of Additively Manufactured Ti-6al-4v — Comparison Among Selective Laser Melting, Electron Beam Melting, Laser Metal Deposition And Selective Laser Sintering, And With Conventional Powder”, Sinter. Tech. Mater., Ss. 76–106, 2015.
• A. Vlasea, M., Lane, B., Lopez, F., Mekhontsev, S., Donmez, “Development Of Powder Bed Fusıon Addıtıve Manufacturıng Test Bed For Enhanced Real-Tıme Process Control”, Proc. Int. Solid Free. Fabr. Symp., C. 1, Sayı 1, Ss. 527–539, 2015.
• J. Živčák, M. Šarik, Ve R. Hudák, “Fea Simulation Of Thermal Processes During The Direct Metal Laser Sintering Of Ti64 Titanium Powder”, Measurement, C. 94, Ss. 893–901, 2016.
• O. Kayabaşı, E. Yüzbasıoğlu, Ve F. Erzincanlı, “Static, Dynamic And Fatigue Behaviors Of Dental İmplant Using Finite Element Method”, Adv. Eng. Softw., C. 37, Sayı 10, Ss. 649–658, 2006.
• J. Romano, L. Ladani, Ve M. Sadowski, “Thermal Modeling Of Laser Based Additive Manufacturing Processes Within Common Materials”, Procedia Manuf., C. 1, Ss. 238–250, 2015.
• A. Cerardi, M. Caneri, R. Meneghello, G. Concheri, Ve M. Ricotta, “Mechanical Characterization Of Polyamide Cellular Structures Fabricated Using Selective Laser Sintering Technologies”, Mater. Des., C. 46, Ss. 910–915, 2013.
• G. Campoli, M. S. Borleffs, S. Amin Yavari, R. Wauthle, H. Weinans, Ve A. A. Zadpoor, “Mechanical Properties Of Open-Cell Metallic Biomaterials Manufactured Using Additive Manufacturing”, Mater. Des., C. 49, Ss. 957–965, 2013.
• R. Guo, “Numerical Analysis On Static Mechanical Properties Of The Periodic Multilayer Lattice Material”, Engineering, C. 3, Sayı 12, Ss. 1149–1154, 2011.
• W. Gao, Y. Zhang, D. Ramanujan, K. Ramani, Y. Chen, C. B. Williams, C. C. L. Wang, Y. C. Shin, S. Zhang, Ve P. D. Zavattieri, “The Status, Challenges, And Future Of Additive Manufacturing İn Engineering”, Comput. Des., C. 69, Ss. 65–89, 2015.
• H. W. Mindt, O. Desmaison, M. Megahed, A. Peralta, Ve J. Neumann, “Modeling Of Powder Bed Manufacturing Defects”, J. Mater. Eng. Perform., C. 27, Sayı 1, Ss. 32–43, 2018.
• D. M. Jacobson Ve G. Bennett, “Practical Issues İn The Application Of Direct Metal Laser Sintering”, Solid Free. Fabr. Symp., Ss. 728–739, 2006.
• M. L. Vlasea, B. Lane, F. Lopez, S. Mekhontsev, Ve A. Donmez, “Development Of Powder Bed Fusion Additive Manufacturing Test Bed For Enhanced Real-Time Process Control”, 26th Annu. Int. Solid Free. Fabr. Symp., Ss. 527–539, 2015.
• S. Mounsey, B. Hon, Ve C. Sutcliffe, “Performance Modelling And Simulation Of Metal Powder Bed Fusion Production System”, Cırp Ann. - Manuf. Technol., C. 65, Sayı 1, Ss. 421–424, 2016.
• A. E. Patterson, S. L. Messimer, Ve P. A. Farrington, “Overhanging Features And The Slm/Dmls Residual Stresses Problem: Review And Future Research Need”, Technologies, C. 5, Sayı 2, S. 15, 2017.
• H. Peng, D. B. Go, R. Billo, S. Gong, M. R. Shankar, B. A. Gatrell, J. Budzinski, P. Ostiguy, R. Attardo, C. Tomonto, J. Neidig, Ve D. Hoelzle, “Part-Scale Model For Fast Prediction Of Thermal Distortion İn Dmls Additive Manufacturing ; Part 1 : A Thermal Cicuit Network Model”, İçinde Proceedings Of The 27th Annual International Solid Freeform Fabrication Symposium, 2016, Ss. 361–381.
• H. Peng, D. B. Go, R. Billo, S. Gong, M. R. Shankar, B. A. Gatrell, J. Budzinski, P. Ostiguy, R. Attardo, C. Tomonto, J. Neidig, Ve D. Hoelzle, “Part-Scale Model For Fast Prediction Of Thermal Distortion İn Dmls Additive Manufacturing ; Part 2 : A Quasistatic Thermomechanical Model”, İçinde Proceedings Of The 27th Annual International Solid Freeform Fabrication Symposium, 2016, Ss. 382–397.
• Y. Gaoa, J. Xingb, J. Zhanga, N. Luoa, Ve H. Zheng, “Research On Measurement Method Of Selective Laser Sintering (Sls) Transient Temperature”, Opt. Opt., C. 119, Ss. 1–6, 2007.
• J. Lee Ve V. Prabhu, “Simulation Modeling For Optimal Control Of Additive Manufacturing Processes”, Addit. Manuf., 2016.
• B. Lane, S. Moylan, E. P. Whitenton, Ve L. Ma, “Thermographic Measurements Of The Commercial Laser Powder Bed Fusion Process At Nıst”, Rapid Prototyp. J., C. 22, Sayı 5, Ss. 778–787, 2016.
• B. Lane, E. Whitenton, Ve S. Moylan, “Multiple Sensor Detection Of Process Phenomena İn Laser Powder Bed Fusion”, Thermosense Therm. Infrared Appl., C. 9861, Sayı 986104–1, Ss. 1–9, 2016.
• J. C. Heigel Ve B. M. Lane, “Measurement Of The Melt Pool Length During Single Scan Tracks İn A Commercial Laser Powder Bed Fusion Process”, Vol. 2 Addit. Manuf. Mater., Sayı April, S. V002t01a045, 2017.
• A. J. Dunbar, E. R. Denlinger, M. F. Gouge, T. W. Simpson, Ve P. Michaleris, “Comparisons Of Laser Powder Bed Fusion Additive Manufacturing Builds Through Experimental İn Situ Distortion And Temperature Measurements”, Addit. Manuf., C. 15, Ss. 57–65, 2017.
• T. Keller, G. Lindwall, S. Ghosh, L. Ma, B. M. Lane, F. Zhang, U. R. Kattner, E. A. Lass, J. C. Heigel, Y. Idell, M. E. Williams, A. J. Allen, J. E. Guyer, Ve L. E. Levine, “Application Of Finite Element, Phase-Field, And Calphad-Based Methods To Additive Manufacturing Of Ni-Based Superalloys”, Acta Mater., C. 139, Ss. 244–253, 2017.
• L. E. Criales, Y. M. Arısoy, B. Lane, S. Moylan, A. Donmez, Ve T. Özel, “Predictive Modeling And Optimization Of Multi-Track Processing For Laser Powder Bed Fusion Of Nickel Alloy 625”, Addit. Manuf., C. 13, Ss. 14–36, 2017.
• L. Ma, J. Fong, B. Lane, S. Moylan, J. Filliben, A. Heckert, Ve L. Levine, “Using Design Of Experiments İn Finite Element Modeling To Identify Critical Variables For Laser Powder Bed Fusion”, Solid Free. Fabr. Symp., Ss. 219–228, 2015.
• I. Yadroitsava Ve I. Yadroitsev, “Residual Stress İn Metal Specimens Produced By Direct Metal Laser Sintering”, J. Chem. Inf. Model., C. 53, Sayı 9, Ss. 1689–1699, 2013.
• F. State, “Resıdual Stresses In Dırect Metal Laser Sıntered Parts”, Interim Interdiscip. J., C. 14, Sayı 1, Ss. 110–123, 2015.
• C. Yan, L. Hao, A. Hussein, S. L. Bubb, P. Young, Ve D. Raymont, “Evaluation Of Light-Weight Alsi10mg Periodic Cellular Lattice Structures Fabricated Via Direct Metal Laser Sintering”, J. Mater. Process. Technol., C. 214, Sayı 4, Ss. 856–864, 2014.
• W. F. Mitchell, D. C. Lang, T. A. Merdes, E. W. Reutze, Ve G. S. Welsh, “Dımensıonal Accuracy Of Tıtanıum Dırect Metal Laser Sıntered”, İçinde Proceedings Of The 27th Annual International Solid Freeform Fabrication Symposium, 2016, Ss. 2029–2042.