Influence of High-Productivity Process Parameters on the Surface Quality and Residual Stress State of AISI 316L Components Produced by Directed Energy Deposition

AbstractThe production of large components is one of the most powerful applications of laser powder-directed energy deposition (LP-DED) processes. High productivity could be achieved, when focusing on industrial applications, by selecting the proper process parameters. However, it is of crucial importance to understand the strategies that are necessary to increase productivity while maintaining the overall part quality and minimizing the need for post-processing. In this paper, an analysis of the dimensional deviations, surface roughness and subsurface residual stresses of samples produced by LP-DED is described as a function of the applied energy input. The aim of this work is to analyze the effects of high-productivity process parameters on the surface quality and the mechanical characteristics of the samples. The obtained results show that the analyzed process parameters affect the dimensional deviations and the residual stresses, but have a very little influence on surface roughness, which is instead dominated by the presence of unmelted particles

An investigation on the effect of deposition pattern on the microstructure, mechanical properties and residual stress of 316L produced by Directed Energy Deposition

Abstract In this work, 316L cubes were produced by Directed Energy Deposition (DED) process. To evaluate the effect of deposition patterns on the microstructure, mechanical performance and residual stress of 316L samples, two different deposition strategies are selected (67° and 90°). The general microstructure is revealed, and then the effect of deposition pattern on the microstructure of 316L alloy is evaluated through the Primary Cellular Arm Spacing (PCAS) analysis. The cooling rate in each sample is estimated according to the PCAS values. Interestingly, it is found that by increasing the rotation angle per layer, the PCAS value decreases as a consequence of increment in the cooling rate. On the other hand, in both cases, by increasing the distance from the substrate, due to the changes in cooling mechanisms, the cooling rate at first decreases and then at the last layers increases again. The phase composition analysis of 316L samples confirms the predictions that suggested the presence of residual δ-ferrite in the final microstructure. In fact, the final microstructure of samples is characterized by austenitic dendrites together with some residual δ-ferrite in the interdendritic regions. Moreover, the microstructural evaluations exhibit that during the DED process, some metallic inclusions are formed within the 316L samples that consequently deteriorates their mechanical properties. Tensile results show that the samples with 90° rotation per layer have a better mechanical performance such as slightly higher ultimate tensile strength and almost 35% higher elongation to fracture, mainly owing to their finer microstructure and slightly less oxide content. However, in both cases, the elongation of the 316L samples is lower than the typical elongation of this material produced via DED. This discrepancy is found to be as a result of higher inclusions contents in the samples produced in this work with respect to those of literature. Lastly, it is found that the residual stresses on the top surfaces are similar for both deposition patterns, although higher stress values are observed on the lateral surfaces of the cubes produce using the 90° rotation per layer

On the Effect of Part Orientation on Stress Distribution in AlSi10Mg Specimens Fabricated by Laser Powder Bed Fusion (L-PBF)

Abstract The freedom of design of AM products suffers from some limitations in case of powder bed metal processes, because AM part's integrity is affected by the residual stress state that is a consequence of the thermal history during part fabrication. Aim of this work is to evaluate the effect of part orientation on stress distribution. Thus, flat samples of AlSi10Mg alloy built along different orientations are produced by means of laser powder bed fusion (L-PBF) process, also known as Selective Laser Melting (SLM). Then, the semi-destructive hole-drilling method is used to evaluate residual stresses beneath the surfaces of samples. The outcomes of the study can be exploited to define design rules in order to both minimize support structures and optimize the orientation of the part in the building volume

Numerical modelling of heat transfer and experimental validation in Powder-Bed Fusion with the Virtual Domain Approximation

Among metal additive manufacturing technologies, powder-bed fusion features very thin layers and rapid solidification rates, leading to long build jobs and a highly localized process. Many efforts are being devoted to accelerate simulation times for practical industrial applications. The new approach suggested here, the virtual domain approximation, is a physics-based rationale for spatial reduction of the domain in the thermal finite-element analysis at the part scale. Computational experiments address, among others, validation against a large physical experiment of 17.5 $\mathrm{[cm^3]}$ of deposited volume in 647 layers. For fast and automatic parameter estimation at such level of complexity, a high-performance computing framework is employed. It couples FEMPAR-AM, a specialized parallel finite-element software, with Dakota, for the parametric exploration. Compared to previous state-of-the-art, this formulation provides higher accuracy at the same computational cost. This sets the path to a fully virtualized model, considering an upwards-moving domain covering the last printed layers

machining induced residual stresses in alsi10mg component produced by laser powder bed fusion l pbf

Abstract The adoption of metal powder-based laser process (L-PBF) for industrial applications continues to widen, due to an increasing knowledge on additive processes and the availability of new systems for industrial production. The use of L-PBF processes requires a deeper investigation and comparison on mechanical properties of conventional and additive parts. For instance, metal parts produced by L-PBF could require additional machining operations, which alter the stress state of additive components. In this work, the effect of machining operations on the residual stress state of an AlSi10Mg component produced by L-PBF is investigated by means of the semi destructive hole-drilling method

Measurement of Sea Waves

Sea waves constitute a natural phenomenon with a great impact on human activities, and their monitoring is essential for meteorology, coastal safety, navigation, and renewable energy from the sea. Therefore, the main measurement techniques for their monitoring are here reviewed, including buoys, satellite observation, coastal radars, shipboard observation, and microseism analysis. For each technique, the measurement principle is briefly recalled, the degree of development is outlined, and trends are prospected. The complementarity of such techniques is also highlighted, and the need for further integration in local and global networks is stressed

Analysis of single tracks of IN718 produced by laser powder directed energy deposition process

Despite the powerful capabilities of the Laser Powder Directed Energy Deposition (LP-DED) process, the applications are limited almost to feasibility analyses of simple case studies. This arises from the knowledge gap in the process parameters identification and optimization of the deposition quality. A practical approach is to delineate the process parameters window by producing single tracks with different sets of parameter levels. This paper aims to study, through statistical analysis, the effect of process parameters on the characteristic dimensions of IN718 single tracks. Results will allow empirical relations to be identified between track geometry and the analysed parameters. These relations will support process optimization

Cardiac sympathetic dysfunction in pulmonary arterial hypertension: Lesson from left-sided heart failure

Sympathetic nervous system hyperactivity has a well-recognized role in the pathophysiology of heart failure with reduced left ventricular ejection fraction. Alterations in sympathetic nervous system have been related to the pathophysiology of pulmonary arterial hypertension, but it is unclear whether cardiac sympathetic nervous system is impaired and how sympathetic dysfunction correlates with hemodynamics and clinical status in pulmonary arterial hypertension patients. The aim of this study was to evaluate the cardiac sympathetic nervous system activity by means of 123Iodine-metaiodobenzylguanidine nuclear imaging in pulmonary arterial hypertension patients and to explore its possible correlation with markers of disease severity. Twelve consecutive pulmonary arterial hypertension patients (nine women, median age 56.5 (17.8), eight idiopathic and four connective tissue-associated pulmonary arterial hypertension) underwent cardiac 123Iodine-metaiodobenzylguanidine scintigraphy. The results were compared with those of 12 subjects with a negative history of cardiovascular or pulmonary disease who underwent the same nuclear imaging test because of a suspected paraganglioma or pheochromocytoma, with a negative result (controls), and 12 patients with heart failure with reduced left ventricular ejection fraction. Hemodynamics, echocardiography, six-minute walking distance, cardiopulmonary exercise testing, and N-terminal pro brain natriuretic peptide were collected in pulmonary arterial hypertension patients within one week from 123Iodine-metaiodobenzylguanidine scintigraphy. Cardiac 123Iodine-metaiodobenzylguanidine uptake, assessed as early and late heart-to-mediastinum ratio, was significantly lower in pulmonary arterial hypertension compared to controls (p = 0.001), but similar to heart failure with reduced left ventricular ejection fraction. Myocardial 123Iodine-metaiodobenzylguanidine turnover, expressed as washout rate, was similar in pulmonary arterial hypertension and heart failure with reduced left ventricular ejection fraction and significantly higher compared to controls (p = 0.016). In the pulmonary arterial hypertension group, both early and late heart-to-mediastinum ratios and washout rate correlated with parameters of pulmonary arterial hypertension severity including pulmonary vascular resistance, right atrial pressure, tricuspid annular plane systolic excursion, N-terminal pro brain natriuretic peptide, and peak VO2. Although we evaluated a small number of subjects, our study showed a significant impairment in cardiac sympathetic nervous system in pulmonary arterial hypertension, similarly to that observed in heart failure with reduced left ventricular ejection fraction. This impairment correlated with indices of pulmonary arterial hypertension severity. Cardiac sympathetic dysfunction may be a contributing factor to the development of right-sided heart failure in pulmonary arterial hypertension