Metal additive manufacturing using electron beam melting (EBM) process applies electron beam for heating, sintering, and melting of powders to fabricate a three-dimensional component. The component may contain residual porosity internally and may be subjected to poor surface finish externally. To improve the quality of the surface finish and densification, re-melting is conducted. The purpose of this paper was to estimate the appropriate process conditions for a plasma electron beam remelting process using heat transfer finite element analyses (FEAs). The impact of the travel speed of table and thickness of the deposited part on temperature distributions were examined. The size of molten pool was estimated from the results of the thermal FEA. From the estimated size of molten pool, the travel speed of table and the hatch spacing between remelting tracks are discussed and selected as the appropriate process conditions for electron beam re-melting process from the perspective of minimum overlapping region of the molten pool.
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Investigation of elimination of powder spreading in manufacture of thin and wide preheating beads from Co–Cr alloy powders using a P-ebeam Ho-Jin Lee, Dong-Gyu Ahn Journal of Materials Research and Technology.2021; 14: 1873. CrossRef
It is compelling to realize that the additive manufactured part using wire feeding type directed energy deposition (DED) process is subjected to undesired thermal effects, and induced residual stress during the manufacturing process. In order to improve the quality of the manufactured part, the distributions of temperature and residual stress have to be understood to manage the results of the processing of these materials. The objective of this paper is to investigate the influence of the angle of corner deposition on the distributions of temperature and residual stress of the Ti-6Al-4V deposited bead, and the substrate via thermo-mechanical finite element analyses (FEAs). In the same fashion, the formation of the heat affected zone (HAZ) and the stress influenced region (SIR) are estimated from the measured results of the FEAs. Equally important, it can be stated that from the estimated HAZ and SIR regions, the overlapping of undesired thermal effects and residual stress between two beads fabricated by the wire feeding type DED process can be avoided at the design stage.
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Estimation Method of Interpass Time for the Control of Temperature during a Directed Energy Deposition Process of a Ti–6Al–4V Planar Layer Bih-Lii Chua, Dong-Gyu Ahn Materials.2020; 13(21): 4935. CrossRef
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Wire feeding type directed energy deposition (DED) process is able to produce metal parts with high density at high deposition rate. However, the parts are subjected to high residual stresses and distortion due to its large heat input. In order to simulate the thermal stress, a proper heat input parameter is required. The goal of this paper is to investigate the efficiency and penetration depth of the applied heat flux in the DED process. The estimation method for the penetration depth and efficiency of applied heat flux is proposed using the thermal finite element analyses (FEAs). A finite element model is developed according to the cross sectional profile of the actual deposited beads. A top-hat volumetric heat flux is adopted to simulate the transient thermal phenomenon of the laser based wire feeding type DED process. The estimated heat affected zone (HAZ) from the FEAs is compared with the experimental results in order to estimate the proper efficiency and penetration depth of the laser beam for each condition of DED process.
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Estimation Method of Interpass Time for the Control of Temperature during a Directed Energy Deposition Process of a Ti–6Al–4V Planar Layer Bih-Lii Chua, Dong-Gyu Ahn Materials.2020; 13(21): 4935. CrossRef
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Influence of process parameters on temperature and residual stress distributions of the deposited part by a Ti-6Al-4V wire feeding type direct energy deposition process Bih Lii Chua, Ho Jin Lee, Dong-Gyu Ahn, Jae Gu Kim Journal of Mechanical Science and Technology.2018; 32(11): 5363. CrossRef
Influence of Angle of Corner Deposition on Temperature and Residual Stress Distributions in the Vicinity of the Deposited Region by a Ti-6Al-4V Wire-Feeding Type of Direct Energy Deposition Process Bih Lii Chua, Ho Jin Lee, Dong-Gyu Ahn, Jae Gu Kim Journal of the Korean Society for Precision Engineering.2018; 35(9): 853. CrossRef
The flexural characteristics of corrugated sandwich panels are anisotropic and depend on its corrugation geometry and load position. The objective of this paper is to examine the influence of corrugation angle and load position on the flexural characteristics of plastic sandwich panels with trapezoidal corrugated cores subjected to ASTM three-point bending via finite element analysis. The stress distributions at mid span have been plotted to determine the stress concentration at different corrugation angle and load position. The specific flexural stiffness and modulus have been estimated from the loaddisplacement and stress-strain curves, respectively. The failure of the specimen due to stress or strain limit has been examined via maximum limit stroke. Results have shown that the specific flexural stiffness and modulus improve as the corrugation angle decreases. The load position has influenced the flexural characteristics due to the occurrence of local bending and local tension.
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