Modeling metal deposition in heat transfer analyses of additive manufacturing processes

Additive Manufacturing (AM) processes for metallic parts using both laser and electron beam heat sources are becoming increasingly popular due to their potential of producing near net shape structural components. The thermal history generated by additive manufacturing is essential in determining the...

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Vydané v:	Finite elements in analysis and design Ročník 86; s. 51 - 60
Hlavný autor:	Michaleris, Panagiotis
Médium:	Journal Article
Jazyk:	English
Vydavateľské údaje:	Elsevier B.V 01.09.2014
Predmet:	Activation Additive manufacturing Additives Deposition Element activation Errors Finite element method Heat transfer Mathematical analysis Mathematical models Metal deposition Near net shaping Metal deposition Additive manufacturing Element activation Heat transfer
ISSN:	0168-874X, 1872-6925
On-line prístup:	Získať plný text
Tagy:	Pridať tag Žiadne tagy, Buďte prvý, kto otaguje tento záznam!

Abstract	Additive Manufacturing (AM) processes for metallic parts using both laser and electron beam heat sources are becoming increasingly popular due to their potential of producing near net shape structural components. The thermal history generated by additive manufacturing is essential in determining the resulting microstructure, material properties, residual stress, and distortion. In this work finite element techniques for modeling metal deposition heat transfer analyses of additive manufacturing are investigated in detail. In particular, both quiet and inactive element activation are reviewed in detail and techniques for minimizing errors associated with element activation errors are proposed. 1D and 3D numerical examples are used to demonstrate that both methods can give equivalent results if implemented properly. It is also shown that neglecting surface convection and radiation on the continuously evolving interface between active and inactive elements can lead to errors. A new hybrid quiet inactive metal deposition method is also proposed to accelerate computer run times. •FEA techniques for modeling metal deposition in additive manufacturing are investigated.•A new hybrid inactive/quiet element method is proposed for modeling additive manufacturing.•Metal deposition element is initially inactive, then, they are switched to quiet layer by layer.
AbstractList	Additive Manufacturing (AM) processes for metallic parts using both laser and electron beam heat sources are becoming increasingly popular due to their potential of producing near net shape structural components. The thermal history generated by additive manufacturing is essential in determining the resulting microstructure, material properties, residual stress, and distortion. In this work finite element techniques for modeling metal deposition heat transfer analyses of additive manufacturing are investigated in detail. In particular, both quiet and inactive element activation are reviewed in detail and techniques for minimizing errors associated with element activation errors are proposed. 1D and 3D numerical examples are used to demonstrate that both methods can give equivalent results if implemented properly. It is also shown that neglecting surface convection and radiation on the continuously evolving interface between active and inactive elements can lead to errors. A new hybrid quiet inactive metal deposition method is also proposed to accelerate computer run times. Additive Manufacturing (AM) processes for metallic parts using both laser and electron beam heat sources are becoming increasingly popular due to their potential of producing near net shape structural components. The thermal history generated by additive manufacturing is essential in determining the resulting microstructure, material properties, residual stress, and distortion. In this work finite element techniques for modeling metal deposition heat transfer analyses of additive manufacturing are investigated in detail. In particular, both quiet and inactive element activation are reviewed in detail and techniques for minimizing errors associated with element activation errors are proposed. 1D and 3D numerical examples are used to demonstrate that both methods can give equivalent results if implemented properly. It is also shown that neglecting surface convection and radiation on the continuously evolving interface between active and inactive elements can lead to errors. A new hybrid quiet inactive metal deposition method is also proposed to accelerate computer run times. •FEA techniques for modeling metal deposition in additive manufacturing are investigated.•A new hybrid inactive/quiet element method is proposed for modeling additive manufacturing.•Metal deposition element is initially inactive, then, they are switched to quiet layer by layer.
Author	Michaleris, Panagiotis
Author_xml	– sequence: 1 givenname: Panagiotis surname: Michaleris fullname: Michaleris, Panagiotis organization: Department of Mechanical and Nuclear Engineering, The Pennsylvania State University, Pan Computing LLC, United States
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Snippet	Additive Manufacturing (AM) processes for metallic parts using both laser and electron beam heat sources are becoming increasingly popular due to their...
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SubjectTerms	Activation Additive manufacturing Additives Deposition Element activation Errors Finite element method Heat transfer Mathematical analysis Mathematical models Metal deposition Near net shaping
Title	Modeling metal deposition in heat transfer analyses of additive manufacturing processes
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