Evaluating residual stresses in metal additive manufacturing: a comprehensive review of detection methods, impact, and mitigation strategies

IF 2.6 3区材料科学 Q2 ENGINEERING, MANUFACTURING International Journal of Material Forming Pub Date : 2024-09-14 DOI:10.1007/s12289-024-01855-7

Mumtaz Rizwee, Deepak Kumar

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Abstract

The metal additive manufacturing (MAM) process has most employed methods to build complex geometry and lightweight 3-dimensional (3-D) parts directly from a computerized solid model. Distortion of the printed part is a highly significant concern within the MAM process. This issue is because of the heating and cooling effect of printing process that could accumulate residual stress (RS) during part building up. The aim of the literature work is to present various methodologies for measuring RS in MAM components and to furnish a brief summary of recent developments in the domain. These details aid scholars in the discernment of suitable techniques, namely destructive, semi-destructive, or non-destructive, contingent on their particular applications and the accessibility of these methods. Moreover, it facilitates the explication of their formation mechanisms, effectiveness of process parameters, prediction, and control techniques. The effect of RS on the mechanical characteristics of printed parts is analyzed and presented. Additionally, common defects incorporated into RS are discussed. Moreover, this review article discusses about the future challenges and opportunities in the RS analysis of MAM parts.

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评估金属增材制造中的残余应力：检测方法、影响和缓解策略综合评述

金属增材制造（MAM）工艺最常用的方法是直接从计算机实体模型中制造几何形状复杂、重量轻的三维（3-D）零件。在 MAM 工艺中，打印部件的变形是一个非常重要的问题。造成这一问题的原因是打印过程中的加热和冷却效应会在零件成型过程中积累残余应力（RS）。本文献旨在介绍测量 MAM 部件 RS 的各种方法，并简要概述该领域的最新发展。这些详细信息有助于学者们根据其特定应用和这些方法的可及性选择合适的技术，即破坏性、半破坏性或非破坏性技术。此外，它还有助于阐述其形成机制、工艺参数的有效性、预测和控制技术。该书分析并介绍了 RS 对印刷部件机械特性的影响。此外，还讨论了 RS 中常见的缺陷。此外，这篇综述文章还讨论了 MAM 零件 RS 分析的未来挑战和机遇。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Material Forming ENGINEERING, MANUFACTURING-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.10

自引率

4.20%

发文量

审稿时长

>12 weeks

期刊介绍： The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material. The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations. All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.