Study on the effect of variable laser power on residual stress distribution in laser directed energy deposition of Ti6Al4V

IF 4.6 2区 工程技术 Q2 ENGINEERING, MANUFACTURING CIRP Journal of Manufacturing Science and Technology Pub Date : 2024-10-23 DOI:10.1016/j.cirpj.2024.10.011
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Abstract

In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.
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研究激光定向能沉积 Ti6Al4V 过程中可变激光功率对残余应力分布的影响
在激光定向能沉积(LDED)工艺中,循环热应力加载会在反复加热过程中引起工件表面和次表面显著的温度变化,导致冷却过程中形成残余拉伸应力。这会对零件的机械性能产生不利影响,导致变形和缺陷。本研究在有限元分析的基础上建立了传热模型和三维应力模型。提出了可变激光功率(VLP)沉积策略,以动态模拟不同沉积策略下 Ti6Al4V 钛合金的温度场和应力场。通过使用热电偶收集基底温度变化并使用 X 射线衍射仪(XRD)测量残余应力,对模型进行了验证。实验结果表明,模拟和实验之间的温度误差在 6.25 % 到 10.12 % 之间,平均应力模拟误差为 6.92 %。在四种策略中,使用 VLP 策略的样品与其他三种策略相比,基底平均温度降低了 12.68 % 至 15.08 %。层中的最大主应力降低了 7.8% 至 32.14%,残余应力在各个方向的分布更加均匀。沉积层的微观结构进一步表明,VLP 策略改善了残余应力分布,从而提高了沉积质量。
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来源期刊
CIRP Journal of Manufacturing Science and Technology
CIRP Journal of Manufacturing Science and Technology Engineering-Industrial and Manufacturing Engineering
CiteScore
9.10
自引率
6.20%
发文量
166
审稿时长
63 days
期刊介绍: The CIRP Journal of Manufacturing Science and Technology (CIRP-JMST) publishes fundamental papers on manufacturing processes, production equipment and automation, product design, manufacturing systems and production organisations up to the level of the production networks, including all the related technical, human and economic factors. Preference is given to contributions describing research results whose feasibility has been demonstrated either in a laboratory or in the industrial praxis. Case studies and review papers on specific issues in manufacturing science and technology are equally encouraged.
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