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Kalel FINAL 05 02 23 with cert.pdf (6.52 MB)

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Thermo-mechanical Analysis of Laser Hot-wire Directed Energy Deposition (LHW-DED) Additive Manufacturing Process

Kalel, Mukesh
http://orcid.org/0009-0000-9946-1533
http://rave.ohiolink.edu/etdc/view?acc_num=ysu1683039378964643

Abstract Details

2023, Master of Science in Engineering, Youngstown State University, Department of Mechanical, Industrial and Manufacturing Engineering.
The field of metal additive manufacturing has experienced significant growth in recent years, and Laser Hot Wire Directed Energy Deposition (LHW-DED) has emerged as a popular technology due to its ease of use and ability to produce high-quality metal parts. In this study, we used a nonlinear transient thermo-mechanical coupled finite element model (FEM) in ANSYS APDL to conduct a detailed thermal and structural analysis of the laser hot wire DED metal additive manufacturing process. This analysis aimed to characterize the distortion caused by thermal effects and investigate the transient thermal process. In this study H13 iron chromium alloy material was deposited on an A36 low carbon steel substrate using a bidirectional laser toolpath. To record the temperature profile during printing, we employed a FLIR Infrared (IR) camera, while thermocouples mounted to the base plate measured heat transfer for validation purposes. Post-processing analysis was conducted using the CREAFORM laser 3D scan and Geomagic-X software to measure deformation from the nominal printed geometry. Overall, this study provides a significant contribution to our understanding of laser hot wire DED metal additive manufacturing, which will undoubtedly lead to further advancements in the field. This research has the potential to improve the productivity and quality of the additive manufacture of metals.
Kyosung Choo, PhD (Advisor)
Jae Joong Ryu, PhD (Committee Member)
Alexander H. Pesch, PhD (Committee Member)
120 p.
Aerospace Materials; Engineering; Materials Science; Mechanical Engineering
Direct Energy Deposition; DED; Additive Manufacturing; AM; Laser Hot wire Direct Energy Deposition; LHW-DED; Finite Element Modeling; FEM; Transient-Thermal ANSYS Simulation; Transient-Structural Simulation; Heat Transfer; 3D Printing Simulation; Thermal - Deformation; Thermal - Distortion; Thermal Validation; Thermo-Mechanical Modeling

Recommended Citations

Citations

  • Kalel, M. (2023). Thermo-mechanical Analysis of Laser Hot-wire Directed Energy Deposition (LHW-DED) Additive Manufacturing Process [Master's thesis, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1683039378964643

    APA Style (7th edition)

  • Kalel, Mukesh. Thermo-mechanical Analysis of Laser Hot-wire Directed Energy Deposition (LHW-DED) Additive Manufacturing Process. 2023. Youngstown State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu1683039378964643.

    MLA Style (8th edition)

  • Kalel, Mukesh. "Thermo-mechanical Analysis of Laser Hot-wire Directed Energy Deposition (LHW-DED) Additive Manufacturing Process." Master's thesis, Youngstown State University, 2023. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1683039378964643

    Chicago Manual of Style (17th edition)

ysu1683039378964643
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© 2023, all rights reserved.
This open access ETD is published by Youngstown State University and OhioLINK.
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