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The Effects of Build Orientation on Residual Stresses in AlSi10Mg Laser Powder Bed Fusion Parts

Clark, Jared A.
http://rave.ohiolink.edu/etdc/view?acc_num=ysu1578819644598848

Abstract Details

2019, Master of Science in Engineering, Youngstown State University, Department of Mechanical, Industrial and Manufacturing Engineering.
Additive manufacturing is one of the more recent advances in manufacturing technology. Additive manufacturing processes allow for the creation of parts in a layer-by-layer fashion. There are several materials that can be used in additive manufacturing processes including metal, ceramic, and polymers which each presenting their own challenges. This work focuses on metal based additive manufacturing parts made out of AlSi10Mg using a process called laser powder bed fusion. Laser powder bed fusion is one of the three major metal additive manufacturing processes with the other two being multi-pass welding and direct energy deposition. One of many challenges that occur with the laser power bed fusion process is minimizing the residual stresses and distortion that are present in the part during and after the build. During the early days of additive manufacturing that was mostly done through a trial-and-error process where multiple version of a part would be printed until a desired outcome was achieved, and this was often very expensive, and time consuming. There has been plenty of research in developing simulation models in order to predict the distortions and stresses that developed during the additive manufacturing process. These simulations allowed engineers to optimize parts before they were printed, and thus reduce the number of wasted prints. This work demonstrates and validates use of a software package call Autodesk Netfabb Simulation in order to find the optimal orientation of a complex part. The optimal orientation was selected for three categories: distortion, stress, and printability. Optimal orientations were selected from a selection of 23 orientations that were simulated. To validate the simulations, two test parts along with three of the aforementioned orientations were printed and measured using 3D scanning while still the build plate. The result of this was that the optimal orientation was different for each of three criteria meaning it is up to the part application to decide which one is best, and measurement techniques used yielded inconclusive results.
Jason Walker, PhD (Advisor)
Brett Conner, PhD (Committee Member)
Virgil Solomon, PhD (Committee Member)
156 p.
Engineering; Mechanical Engineering; Metallurgy
Additive Manufacturing; AlSi10Mg; Autodesk; Autodesk Netfabb; Netfabb; Metal; Aluminum; 3D Scanning; 3D Printing; Residual Stress; Orientation; Optimization; Laser Power Bed Fusion; Power Bed Fusion; Selective Laser Melting; SLM; LPBF

Recommended Citations

Citations

  • Clark, J. A. (2019). The Effects of Build Orientation on Residual Stresses in AlSi10Mg Laser Powder Bed Fusion Parts [Master's thesis, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1578819644598848

    APA Style (7th edition)

  • Clark, Jared. The Effects of Build Orientation on Residual Stresses in AlSi10Mg Laser Powder Bed Fusion Parts. 2019. Youngstown State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu1578819644598848.

    MLA Style (8th edition)

  • Clark, Jared. "The Effects of Build Orientation on Residual Stresses in AlSi10Mg Laser Powder Bed Fusion Parts." Master's thesis, Youngstown State University, 2019. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1578819644598848

    Chicago Manual of Style (17th edition)

ysu1578819644598848
871
© 2019, all rights reserved.
This open access ETD is published by Youngstown State University and OhioLINK.
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