Material characteristics of additively manufactured Ti-6AL-4V samples using the laser based direct energy deposition technique.
DOI:
https://doi.org/10.17159/Abstract
Not with standing additive manufacturing gaining traction fast in the industrial world as a reputable manufacturing technique to complement traditional mechanical machining, it is still plagued with problems such as porosity and residual stresses that give rise to cracking, distortion and delamination that are important parameters to resolve in structural load bearing applications. This undergraduate level research project focused on the characterisation of the evolution of the residual stresses in Ti-6Al-4V ELI additive manufactured test samples. Four square thin-walled tubular samples were deposited on the same baseplate using the direct energy deposition laser printing process to different build heights. The residual stresses were analysed in as-printed condition by the neutron diffraction technique and correlated to qualitative predictions using the ANSYS software suite. Good qualitative agreement between the stress measurements and predictions have been observed. Both approaches revealed the existence of large tensile stresses along the laser track direction at the sections that were built last, i.e., centre of top layers of the samples. This in addition leads to large tensile stresses at the outer edges (corners) that have the effect of wanting to “tear” the samples from the baseplate, should the stresses exceed the yield strength of the material. Such extreme conditions did not occur in this study but did lead to significant distortion of the baseplate. In general, the microstructures and spatial elemental mapping revealed that there was a strong correlation between the macro-segregation of the elemental V and the distribution of the β-phase in the printed parts.Downloads
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