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Publisher DOI: 10.1016/j.procir.2022.08.020
Title: Effect of DED process parameters on distortion and residual stress state of additively manufactured Ti-6Al-4V components during machining
Language: English
Authors: Romanenko, Denys 
Jothi Prakash, Vishnuu 
Kuhn, Tobias 
Möller, Carsten 
Hintze, Wolfgang 
Emmelmann, Claus 
Keywords: Directed Energy Deposition; Residual Stresses; Distortion; Process Parameters; Machining Strategies
Issue Date: Sep-2022
Publisher: Elsevier
Source: Procedia CIRP 111: 271-276 (2022)
Abstract (english): 
One of the major challenges in high-deposition rate Directed Energy Deposition processes is the resultant residual stresses generated during material deposition, often leading to distortion and poor material characteristics. Important part families suitable for DED process in aerospace sector are thin-wall components, characterized by a large base surface area with rib-like strengthening structures. Here, the substrate plate can be designed to be a part of the final component. The integration of substrate plate into final component results in possible deformation due to residual stress release during machining. This paper therefore investigates the effect of various powder-based Laser Metal Deposition process parameters and strategies on the residual stress state of the additively manufactured Ti-6Al-4V components and the resulting stress release during machining process. The analysis has been carried out during the machining process by including in-process strain measurements of the substrate. The embraced layer removal method allows the determination of machining zone specific stress release mapping, based on an analytical and FEM-model. Hence, the initial residual stress state of the builds was calculated, which revealed that although the heat treatment resolved most of the residual stresses, also in heat treated parts residues were identified depending on the part clamping during the treatment. Furthermore, the study revealed that the significant residual stresses are present in the layers close to the substrate.
Conference: 12th CIRP Conference on Photonic Technologies, LANE 2022 
DOI: 10.15480/882.4608
ISSN: 2212-8271
Journal: Procedia CIRP 
Institute: Produktionsmanagement und -technik M-18 
Laser- und Anlagensystemtechnik T-2 
Document Type: Article
Project: Entwicklung und Aufbau einer Fertigungslinie für Titanbauteile mittels eines durch vollständige Vernetzung optimierten Direct-Energy-Deposition-Prozess 
License: CC BY-NC-ND 4.0 (Attribution-NonCommercial-NoDerivatives) CC BY-NC-ND 4.0 (Attribution-NonCommercial-NoDerivatives)
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