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The three-prong method: a novel assessment of residual stress in laser powder bed fusion

S. A. Sillars, C. J. Sutcliffe, Adam Philo, Steve Brown, Johann Sienz Orcid Logo, Nicholas Lavery Orcid Logo

Virtual and Physical Prototyping, Volume: 13, Issue: 1, Pages: 20 - 25

Swansea University Authors: Adam Philo, Steve Brown, Johann Sienz Orcid Logo, Nicholas Lavery Orcid Logo

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DOI (Published version): 10.1080/17452759.2017.1392682

Abstract

Residual stress is a major problem for most metal-based laser powder bed fusion (L-PBF) components. Residual stress can be reduced by appropriate build planning and post-process heat treatments; however, it is not always avoidable and can lead to build failures due to distortion and cracking. Accura...

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Published in: Virtual and Physical Prototyping
ISSN: 1745-2759 1745-2767
Published: Informa UK Limited 2018
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URI: https://cronfa.swan.ac.uk/Record/cronfa36037
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Residual stress can be reduced by appropriate build planning and post-process heat treatments; however, it is not always avoidable and can lead to build failures due to distortion and cracking. Accurate measurement of residual stress levels can be difficult due to high equipment set-up costs and long processing times. This paper introduces a simple but novel method of measuring residual stresses via a three-pronged cantilever component, the three-prong method (TPM). The method allows for a quick and easy characterisation of residual stress for a wide range of machine parameters, build strategies and materials. Many different cantilever designs have been used to indicate residual stress within additive manufacturing techniques. All of which share the same shortcoming that they indicate stress in one direction. If the principal component of stress is not aligned with the beam geometry, it will underestimate peak stress values. A novel three-prong design is proposed which covers two dimensions by utilising three adjoined cantilever beams, a configuration which echoes that of hole-drilling where three measurements are used to calculate the stress field around a drilled hole. Each arm of the component resembles a curved bridge-like structure; one end of each bridge is cut away from the base plate leaving the centre intact. Deformation of the beams is then measured using a co-ordinate measurement machine. Stress profiles are then estimated using finite element analysis by meshing the deflected structure and forcing it back to its original shape. 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spelling 2020-10-23T14:22:35.3584408 v2 36037 2017-10-12 The three-prong method: a novel assessment of residual stress in laser powder bed fusion dabe908638d8dc4e36994f97a79509b9 Adam Philo Adam Philo true false 07a865adc76376646bc6c03a69ce35a9 Steve Brown Steve Brown true false 17bf1dd287bff2cb01b53d98ceb28a31 0000-0003-3136-5718 Johann Sienz Johann Sienz true false 9f102ff59824fd4f7ce3d40144304395 0000-0003-0953-5936 Nicholas Lavery Nicholas Lavery true false 2017-10-12 FGSEN Residual stress is a major problem for most metal-based laser powder bed fusion (L-PBF) components. Residual stress can be reduced by appropriate build planning and post-process heat treatments; however, it is not always avoidable and can lead to build failures due to distortion and cracking. Accurate measurement of residual stress levels can be difficult due to high equipment set-up costs and long processing times. This paper introduces a simple but novel method of measuring residual stresses via a three-pronged cantilever component, the three-prong method (TPM). The method allows for a quick and easy characterisation of residual stress for a wide range of machine parameters, build strategies and materials. Many different cantilever designs have been used to indicate residual stress within additive manufacturing techniques. All of which share the same shortcoming that they indicate stress in one direction. If the principal component of stress is not aligned with the beam geometry, it will underestimate peak stress values. A novel three-prong design is proposed which covers two dimensions by utilising three adjoined cantilever beams, a configuration which echoes that of hole-drilling where three measurements are used to calculate the stress field around a drilled hole. Each arm of the component resembles a curved bridge-like structure; one end of each bridge is cut away from the base plate leaving the centre intact. Deformation of the beams is then measured using a co-ordinate measurement machine. Stress profiles are then estimated using finite element analysis by meshing the deflected structure and forcing it back to its original shape. In this paper, the new TPM is used to compare the residual stress levels of components built in Ti–6Al–4V with different hatch patterns, powers and exposure times. Journal Article Virtual and Physical Prototyping 13 1 20 25 Informa UK Limited 1745-2759 1745-2767 Laser powder bed fusion, residual stress, additive manufacturing, 3D printing, selective laser melting 2 1 2018 2018-01-02 10.1080/17452759.2017.1392682 COLLEGE NANME Science and Engineering - Faculty COLLEGE CODE FGSEN Swansea University 2020-10-23T14:22:35.3584408 2017-10-12T13:11:40.1674623 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised S. A. Sillars 1 C. J. Sutcliffe 2 Adam Philo 3 Steve Brown 4 Johann Sienz 0000-0003-3136-5718 5 Nicholas Lavery 0000-0003-0953-5936 6 0036037-09112017160106.pdf sillars2017.pdf 2017-11-09T16:01:06.4730000 Output 429867 application/pdf Accepted Manuscript true 2018-11-05T00:00:00.0000000 true eng
title The three-prong method: a novel assessment of residual stress in laser powder bed fusion
spellingShingle The three-prong method: a novel assessment of residual stress in laser powder bed fusion
Adam Philo
Steve Brown
Johann Sienz
Nicholas Lavery
title_short The three-prong method: a novel assessment of residual stress in laser powder bed fusion
title_full The three-prong method: a novel assessment of residual stress in laser powder bed fusion
title_fullStr The three-prong method: a novel assessment of residual stress in laser powder bed fusion
title_full_unstemmed The three-prong method: a novel assessment of residual stress in laser powder bed fusion
title_sort The three-prong method: a novel assessment of residual stress in laser powder bed fusion
author_id_str_mv dabe908638d8dc4e36994f97a79509b9
07a865adc76376646bc6c03a69ce35a9
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9f102ff59824fd4f7ce3d40144304395
author_id_fullname_str_mv dabe908638d8dc4e36994f97a79509b9_***_Adam Philo
07a865adc76376646bc6c03a69ce35a9_***_Steve Brown
17bf1dd287bff2cb01b53d98ceb28a31_***_Johann Sienz
9f102ff59824fd4f7ce3d40144304395_***_Nicholas Lavery
author Adam Philo
Steve Brown
Johann Sienz
Nicholas Lavery
author2 S. A. Sillars
C. J. Sutcliffe
Adam Philo
Steve Brown
Johann Sienz
Nicholas Lavery
format Journal article
container_title Virtual and Physical Prototyping
container_volume 13
container_issue 1
container_start_page 20
publishDate 2018
institution Swansea University
issn 1745-2759
1745-2767
doi_str_mv 10.1080/17452759.2017.1392682
publisher Informa UK Limited
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
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description Residual stress is a major problem for most metal-based laser powder bed fusion (L-PBF) components. Residual stress can be reduced by appropriate build planning and post-process heat treatments; however, it is not always avoidable and can lead to build failures due to distortion and cracking. Accurate measurement of residual stress levels can be difficult due to high equipment set-up costs and long processing times. This paper introduces a simple but novel method of measuring residual stresses via a three-pronged cantilever component, the three-prong method (TPM). The method allows for a quick and easy characterisation of residual stress for a wide range of machine parameters, build strategies and materials. Many different cantilever designs have been used to indicate residual stress within additive manufacturing techniques. All of which share the same shortcoming that they indicate stress in one direction. If the principal component of stress is not aligned with the beam geometry, it will underestimate peak stress values. A novel three-prong design is proposed which covers two dimensions by utilising three adjoined cantilever beams, a configuration which echoes that of hole-drilling where three measurements are used to calculate the stress field around a drilled hole. Each arm of the component resembles a curved bridge-like structure; one end of each bridge is cut away from the base plate leaving the centre intact. Deformation of the beams is then measured using a co-ordinate measurement machine. Stress profiles are then estimated using finite element analysis by meshing the deflected structure and forcing it back to its original shape. In this paper, the new TPM is used to compare the residual stress levels of components built in Ti–6Al–4V with different hatch patterns, powers and exposure times.
published_date 2018-01-02T03:45:01Z
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