Modélisation de la fabrication directe de pièces par projection laser : application au Ti-6Al-4V

International audienceLa projection laser permet de fabriquer de façon relativement simple des pièces complexes, dont les dimensions sont proches des cotes finales. Le procédé s'accompagne néanmoins d'importantes variations locales de température, à l'origine d'une microstructure hétérogène, et de contraintes résiduelles difficiles à maîtriser. Une bonne manière d'aider au développement du procédé est de mettre en place sa simulation numérique, afin de prévoir la microstructure et les contraintes résiduelles. Des conditions laser adaptées et une stratégie de balayage optimisée doivent permettre d'obtenir la microstructure désirée et des contraintes résiduelles minimisées

Laser offset welding of AZ31B magnesium alloy to 316 stainless steel

In this paper, the feasibility of using a fiber laser to perform a dissimilar metal joining was explored. AZ31B magnesium and 316 stainless steel were autogenously joined in butt configuration. The weldability between different materials is often compromised by a large difference in thermal properties and poor metallurgical compatibility. Thus, the beam was focused onto the top surface of the magnesium plate, at a certain distance from the interfaces (offset), and without using any interlayer or groove preparation. Such a method was called laser offset welding (LOW). Results proved a very good capability. The ultimate tensile strength exceeded the value of 100 MPa, since a resistant and thin layer of hard intermetallic compounds is formed within the fusion zone. The rupture was observed within the magnesium side, far from the centerline. The metallurgy of fusion zone indicated the effectiveness of phases coalescence, without mixing at liquid states. LOW was demonstrated to be a promising technique to join dissimilar metal welds, being capable to produce an effective bonding with good tensile strength

Towards a numerical simulation of direct manufacturing of thermoplastic parts by powder laser sintering COMPLAS XI

Direct manufacturing technology using Selective Laser Sintering (SLS) on thermoplastic powders allows obtaining final parts in a short time, with classical polymer density and a high flexibility of shape and evolution of parts. The physical base of this process is the coalescence of grains, which initiates the densification of powder during SLS. This study presents a 2D C-NEM simulation of the whole process. We firstly focus on the chosen method and its advantages. We present the simulation details and validate the modeling through a 2D infinite cylinders coalescence simulation. The mesh of the grain interface is continuously adapted to the local curvature to better capture the coalescence phenomenon. We are able to simulate the sintering of twelve particles laying on a support within some hours

High strain-rate material model validation for laser peening simulation

Finite element modeling can be a powerful tool for predicting residual stresses induced by laser peening; however the sign and magnitude of the stress predictions depend strongly on how the material model captures the high strain rate response. Although a Johnson-Cook formulation is often employed, its suitability for modeling phenomena at very high strain rates has not been rigorously evaluated. In this paper, we address the effectiveness of the Johnson-Cook model, with parameters developed from lower strain rate material data (∼10^3 s^–1), to capture the higher strain rate response (∼10^5–10^6 s^–1) encountered during the laser peening process. Published Johnson-Cook parameters extracted from split Hopkinson bar testing were used to predict the shock response of aluminum samples during high-impact flyer plate tests. Additional quasi-static and split Hopkinson bar tests were also conducted to study the model response in the lower strain rate regime. The overall objective of the research was to ascertain whether a material model based on conventional test data (quasi-static compression testing and split Hopkinson bar measurements) can credibly be used in FE simulations to predict laser peen-induced stresses

Aluminum to titanium laser welding-brazing in V-shaped grooveI

Laser assisted joining of AA5754 aluminum alloy to T40 titanium with use of Al-Si filler wires was carried out. Continuous Yb:YAG laser beam was shaped into double spot tandem and defocalized to cover larger interaction zone in V shaped groove. Experimental design method was applied to study the influence of operational parameters on the tensile properties of the joints. Microstructure examination and fractography study were carried out to understand the relation between local phase content and fracture mode. Within defined window of operational parameters, statistically important factors that influenced the strength of T40 to AA5754 joints in V groove configuration were Si content in the filler metal and groove opening angle on T40 side. The best quality joint showed joint coefficient of 90% (or 200 MPa of apparent UTS). Tensile strength of the joints was found to be determined by the proportion between well-developed and under-developed reaction zones of T40/melted zone interface. The formation of 2–25 μm thick Si-rich interlayers composed by Ti5Si3 and τ2 proved to enhance the strength of brazed interface. The creation of very thin (<0.5 μm) Si-rich layers at the bottom of the groove was found not sufficient to establish mechanical continuity of the joint and thus should be avoided

Shapes of leading tunnelling trajectories for single-electron molecular ionization

Based on the geometrical approach to tunnelling by P.D. Hislop and I.M. Sigal [Memoir. AMS 78, No. 399 (1989)], we introduce the concept of a leading tunnelling trajectory. It is then proven that leading tunnelling trajectories for single-active-electron models of molecular tunnelling ionization (i.e., theories where a molecular potential is modelled by a single-electron multi-centre potential) are linear in the case of short range interactions and "almost" linear in the case of long range interactions. The results are presented on both the formal and physically intuitive levels. Physical implications of the obtained results are discussed.Comment: 14 pages, 5 figure

Influence of gas atmosphere (Ar or He) on the laser powder bed fusion of a Ni-based alloy

The gaseous atmosphere plays a major role in the quality of the manufactured parts in Laser Powder Bed Fusion (L-PBF) by protecting the metal from high temperature oxidation. If argon and nitrogen are the most commonly used gases, helium has almost never been considered as a possible candidate as a chemically inert shielding gas. To provide a better understanding of the influence of the gas atmosphere on the process stability, a comparative study of L-PBF manufacturing under argon and helium atmospheres has been carried out, considering a nickel-based alloy Inconel® 625 and a single bead configuration. To this end, in-situ process measurements were carried out on a dedicated experimental setup. The melt pool behaviour, the expansion of the vapour plume and the amount of spatters were evaluated with high-speed imaging for the two gases considered, together with the final L-PBF bead dimensions. Results were also compared to single fusion beads carried out in an industrial L-PBF machine for a comparable range of volume energy densities. The influence of the shielding atmosphere on L-PBF single beads was as follows: (1) dimensions of beads were shown to be constant whatever the gas; (2) fewer and smaller spatters were produced under helium atmosphere, especially for high volume energy densities. Physical mechanisms were then discussed to understand those specific effects

Additive layer manufacturing of titanium matrix composites using the direct metal deposition laser process

Titanium Matrix Composites (TMC's) containing various volume fractions of (TiB+TiC) particles have been deposited from powder feedstocks consisting of a blend of pre-alloyed (Ti-6Al-4V+B4C) powders, using the direct metal deposition (DMD) laser process and the in-situ chemical reaction 5Ti+B4C→4TiB+TiC. Process optimization has allowed to obtain a homogeneous distribution of tiny TiB whiskers within the Ti-6Al-4V α/β matrix, with a full solubilization of C for low B4C contents (0.5 wt% and 1.5 wt%), and the formation of a small amount of globular TiC particles at higher B4C content (3%). Comparisons with Ti-6Al-4V DMD walls revealed a substantial grain refinement on TMC's due to enhanced grain nucleation on TiB whiskers, even for low B4C contents. Last, mechanical investigations indicated an increase of 10–15% of Vickers hardness, and a constant 10% increase of Young modulus on a large temperature range (20–600 °C) for all B4C conten