TY - CHAP

T1 - Thermal analysis of laser additive manufacturing of aluminium alloys: Experiment and simulation

AU - Bock, Frederic E.

AU - Frönd, Martin

AU - Herrnring, Jan

AU - Enz, Josephin

AU - Kashaev, Nikolai

AU - Klusemann, Benjamin

N1 - Conference code: 21

PY - 2018/5/2

Y1 - 2018/5/2

N2 - Laser additive manufacturing (LAM) has become increasingly popular in industry in recent decades because it enables exceptional degrees of freedom regarding the structural design of lightweight components compared to subtractive manufacturing techniques. Laser metal deposition (LMD) of wire-fed material shows in particular the advantages such as high process velocity and efficient use of material compared to other LAM processes. During wire-based LMD, the material is deposited onto a substrate and supplemented by successive layers allowing a layer-wise production of complex three-dimensional structures. Despite the increased productivity of LMD, regarding the ability to process aluminium alloys, there is still a lack in quality and reproducibility due to the inhomogeneous temperature distribution during the process, leading to undesired residual stresses, distortions and inconsistent layer geometries and poor microstructures. In this study, the aluminium alloy AA5087 as wire and AA5754 as substrate material were utilized for LMD. In order to obtain information about the temperature field during LMD, thermocouple and thermography measurements were performed during the process. The temperature measurements were used to validate a finite element model regarding the heat distribution, which will be further used to investigate the temperature field evolution over time. To consider the continuous addition of material within the FE-model, an inactive/active element approach was chosen, where initially deactivated elements are activated corresponding to the deposition of material. The first results of the simulation and the experiments show good agreement. Therefore, the model can be used in the future for LMD process optimization, e.g., in terms of minimizing local variations of the thermal load for each layer

AB - Laser additive manufacturing (LAM) has become increasingly popular in industry in recent decades because it enables exceptional degrees of freedom regarding the structural design of lightweight components compared to subtractive manufacturing techniques. Laser metal deposition (LMD) of wire-fed material shows in particular the advantages such as high process velocity and efficient use of material compared to other LAM processes. During wire-based LMD, the material is deposited onto a substrate and supplemented by successive layers allowing a layer-wise production of complex three-dimensional structures. Despite the increased productivity of LMD, regarding the ability to process aluminium alloys, there is still a lack in quality and reproducibility due to the inhomogeneous temperature distribution during the process, leading to undesired residual stresses, distortions and inconsistent layer geometries and poor microstructures. In this study, the aluminium alloy AA5087 as wire and AA5754 as substrate material were utilized for LMD. In order to obtain information about the temperature field during LMD, thermocouple and thermography measurements were performed during the process. The temperature measurements were used to validate a finite element model regarding the heat distribution, which will be further used to investigate the temperature field evolution over time. To consider the continuous addition of material within the FE-model, an inactive/active element approach was chosen, where initially deactivated elements are activated corresponding to the deposition of material. The first results of the simulation and the experiments show good agreement. Therefore, the model can be used in the future for LMD process optimization, e.g., in terms of minimizing local variations of the thermal load for each layer

KW - Engineering

KW - Additive manufacturing technology

KW - Simulation

KW - Experiment

UR - http://www.scopus.com/inward/record.url?scp=85047313588&partnerID=8YFLogxK

U2 - 10.1063/1.5034996

DO - 10.1063/1.5034996

M3 - Article in conference proceedings

T3 - AIP Conference Proceedings

BT - Proceedings of the 21st International ESAFORM Conference on Material Forming, ESAFORM 2018

A2 - Buffa, Gianluca

A2 - Fratini, Livan

A2 - Ingarao, Giuseppe

A2 - Di Lorenzo, Rosa

PB - American Institute of Physics Inc.

T2 - 21st International Conference on Material Forming - ESAFORM 2018

Y2 - 23 April 2018 through 25 April 2018

ER -