Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation
The performance of the selective electron beam melting (SEBM) products depends on the SEBM-induced temperature and stress. Here, the thermomechanical finite element simulations are conducted to investigate the dynamic evolution of temperature and the thermal stress of melt pool during the SEBM proce...
Saved in:
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-01-01
|
| Series: | Metals |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-4701/15/1/83 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1832587906511798272 |
|---|---|
| author | Qihong Fang Pei Zhao Jia Li Hong Wu Jing Peng |
| author_facet | Qihong Fang Pei Zhao Jia Li Hong Wu Jing Peng |
| author_sort | Qihong Fang |
| collection | DOAJ |
| description | The performance of the selective electron beam melting (SEBM) products depends on the SEBM-induced temperature and stress. Here, the thermomechanical finite element simulations are conducted to investigate the dynamic evolution of temperature and the thermal stress of melt pool during the SEBM process of Ti6Al4V alloys under various processing parameters and scanning strategies. The results show that the melt pool undergoes three stages of preheating, melting, and remelting under the influence of adjacent scanning tracks. This complex thermal history drives significant changes in thermal stress within the melt pool. After adjusting the processing parameters, it is found that a low scanning speed and high electron beam energy result in a high temperature gradient and stress in the molten pool. Compared to the electron beam energy, the scanning speed has a more significant impact on temperature and residual stress. For the dual-electron-beam scanning strategy, the coupling thermal effect between electron beams can reduce the temperature gradient of the melt pool, thereby suppressing the formation of columnar crystals. The electron beam energy of 300 W and the scanning speed of 1.5 m/s can be selected under various scanning strategies, which are expected to suppress the formation of coarse and columnar β grains and achieve relatively low residual stress. These results contribute to providing a theoretical basis for selecting optimized process parameters and scanning strategies. |
| format | Article |
| id | doaj-art-20588397c5bc4cc6b6054fe7b8537782 |
| institution | Kabale University |
| issn | 2075-4701 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj-art-20588397c5bc4cc6b6054fe7b85377822025-01-24T13:41:37ZengMDPI AGMetals2075-47012025-01-011518310.3390/met15010083Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element SimulationQihong Fang0Pei Zhao1Jia Li2Hong Wu3Jing Peng4State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, ChinaState Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, ChinaState Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, ChinaState Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, ChinaState Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, College of Mechanical and Vehicle Engineering, Hunan University, Changsha 410082, ChinaThe performance of the selective electron beam melting (SEBM) products depends on the SEBM-induced temperature and stress. Here, the thermomechanical finite element simulations are conducted to investigate the dynamic evolution of temperature and the thermal stress of melt pool during the SEBM process of Ti6Al4V alloys under various processing parameters and scanning strategies. The results show that the melt pool undergoes three stages of preheating, melting, and remelting under the influence of adjacent scanning tracks. This complex thermal history drives significant changes in thermal stress within the melt pool. After adjusting the processing parameters, it is found that a low scanning speed and high electron beam energy result in a high temperature gradient and stress in the molten pool. Compared to the electron beam energy, the scanning speed has a more significant impact on temperature and residual stress. For the dual-electron-beam scanning strategy, the coupling thermal effect between electron beams can reduce the temperature gradient of the melt pool, thereby suppressing the formation of columnar crystals. The electron beam energy of 300 W and the scanning speed of 1.5 m/s can be selected under various scanning strategies, which are expected to suppress the formation of coarse and columnar β grains and achieve relatively low residual stress. These results contribute to providing a theoretical basis for selecting optimized process parameters and scanning strategies.https://www.mdpi.com/2075-4701/15/1/83selective electron beam meltingfinite element modelstemperature fieldresidual stressscanning strategy |
| spellingShingle | Qihong Fang Pei Zhao Jia Li Hong Wu Jing Peng Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation Metals selective electron beam melting finite element models temperature field residual stress scanning strategy |
| title | Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation |
| title_full | Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation |
| title_fullStr | Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation |
| title_full_unstemmed | Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation |
| title_short | Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation |
| title_sort | unveiling temperature distribution and residual stress evolution of additively manufactured ti6al4v alloy a thermomechanical finite element simulation |
| topic | selective electron beam melting finite element models temperature field residual stress scanning strategy |
| url | https://www.mdpi.com/2075-4701/15/1/83 |
| work_keys_str_mv | AT qihongfang unveilingtemperaturedistributionandresidualstressevolutionofadditivelymanufacturedti6al4valloyathermomechanicalfiniteelementsimulation AT peizhao unveilingtemperaturedistributionandresidualstressevolutionofadditivelymanufacturedti6al4valloyathermomechanicalfiniteelementsimulation AT jiali unveilingtemperaturedistributionandresidualstressevolutionofadditivelymanufacturedti6al4valloyathermomechanicalfiniteelementsimulation AT hongwu unveilingtemperaturedistributionandresidualstressevolutionofadditivelymanufacturedti6al4valloyathermomechanicalfiniteelementsimulation AT jingpeng unveilingtemperaturedistributionandresidualstressevolutionofadditivelymanufacturedti6al4valloyathermomechanicalfiniteelementsimulation |