ECCOMAS 2024

Numerical analysis of SLM-engineered metallic components with focus on process parameters

  • Heider, Yousef (Leibniz University Hannover)
  • Ali, Baharin (RWTH Aachen University)
  • Aldakheel, Fadi (Leibniz University Hannover)

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Selective Laser Melting (SLM), an additive manufacturing (AM) technique, utilizes a focused laser beam to selectively fuse powdered material, constructing 3D objects layer by layer. However, despite its remarkable capabilities, SLM production of metallic components often presents challenges that directly impact the performance and functionality of the manufactured parts. These challenges include residual stresses and deformations, which can lead to an increased risk of warping. Additionally, the presence of voids or empty spaces within the SLM-produced component can significantly diminish the part's mechanical properties, reduce its structural integrity, and increase its susceptibility to crack formation. The presentation offers a numerical investigation into how scanning speed influences the occurrence and intensity of residual stress, as well as the formation of voids or empty spaces and their impact on the tensile strength of the resulting element. This study is based on an advanced thermomechanical continuum model discussed in [1]. It employs a phase-field method to monitor the progression of melting/remelting-solidification events, coupled with a plasticity model [2] that aids in determining the distribution of residual stresses. In addressing the presence of voids in the manufactured structural components, we will introduce a residual porosity function derived from experimental observations of this phenomenon. Furthermore, the integration of a phase-field fracture model will establish correlations among scanning speed, residual stresses, and residual voids, influencing the tensile strength of the manufactured components. The presentation will include numerical examples illustrating the implementation of this coupled system of equations using the open-source FEniCS Project. REFERENCES [1] Ali, B., Heider, Y., & Markert, B. (2024). Predicting residual stresses in SLM additive manufacturing using a phase-field thermomechanical modeling framework. Computational Materials Science, 231, 112576. [2] Aldakheel, F., Miehe, C. (2017). Coupled thermomechanical response of gradient plasticity, Int. J. Plast. 91 , 1–24.