Multiscale investigation on surface integrity and performance of metal parts by selective laser melting

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dc.contributor Allison, Paul Galon
dc.contributor Barkey, Mark E.
dc.contributor Brewer, Luke N.
dc.contributor Jordon, J. Brian
dc.contributor Weaver, Mark Lovell
dc.contributor.advisor Guo, Yuebin B.
dc.contributor.author Li, Chao
dc.date.accessioned 2018-07-11T16:49:05Z
dc.date.available 2018-07-11T16:49:05Z
dc.date.issued 2018
dc.identifier.other u0015_0000001_0002933
dc.identifier.other Li_alatus_0004D_13395
dc.identifier.uri http://ir.ua.edu/handle/123456789/3618
dc.description Electronic Thesis or Dissertation
dc.description.abstract Selective laser melting (SLM) is a popular metal additive manufacturing process which has drawn a great attention in the past decade. It can make functional metal parts directly from the CAD data in a layer upon layer fashion. As-SLMed parts may have near full density comparable to that made by traditional manufacturing methods, SLM has wide application potentials in tool, aerospace, automotive, biomedical, and energy industries. During the SLM process, the interaction between the moving laser beam and the powder leads to very complex physical phenomena. It includes the absorption and reflection of the laser beam; fast heating-cooling cycles; surface tension, wetting, and de-wetting; complex fluid flow and Marangoni convection in the melt pool. Due to the complexity of laser-powder interaction, a comprehensive study of powder-substrate behavior under different process parameters is highly demanded. In addition, high tensile residual stress and part distortion are considered as two major problems for SLMed parts. To understand the formation mechanism of residual stress and part distortion, an efficient prediction tool is highly desired. However, it is very challenging to predict residual stress and distortion of a practical SLMed part as it often requires millions of laser scan which involves the complex multiscale and multi-physics phenomena. Furthermore, poor surface integrity of a SLMed part is detrimental to functional performance such as fatigue. Therefore, a comprehensive understanding of process-surface integrity-fatigue relationship is of great importance. To reveal the underlying mechanisms in SLM, this research focuses on: (1) A critical assessment on the state-of-the-art of SLM process was performed; (2) A thorough characterization of the geometrical, metallurgical, and mechanical properties of single tracks under a broad range of processing conditions in SLM of IN625 alloy; (3) A comprehensive investigation of microstructural evolution of IN625 alloy from as-SLM to different heat treatment conditions; (4) Two efficient multi-physics predictive tools, i.e., stress-thread and temperature-thread based multiscale modeling approaches, to predict residual stress and part distortion of SLMed practical parts at different scanning strategies via thermal loading subroutine and material states variables; (5) A simulation study to investigate the scalability of layer thickness and heat source dimension in fast predicting the distortion and residual stress; and (6) Conclusions and an outlook of the future research.
dc.format.extent 235 p.
dc.format.medium electronic
dc.format.mimetype application/pdf
dc.language English
dc.language.iso en_US
dc.publisher University of Alabama Libraries
dc.relation.ispartof The University of Alabama Electronic Theses and Dissertations
dc.relation.ispartof The University of Alabama Libraries Digital Collections
dc.relation.hasversion born digital
dc.rights All rights reserved by the author unless otherwise indicated.
dc.subject.other Mechanical engineering
dc.title Multiscale investigation on surface integrity and performance of metal parts by selective laser melting
dc.type thesis
dc.type text
etdms.degree.department University of Alabama. Dept. of Mechanical Engineering
etdms.degree.discipline Mechanical Engineering
etdms.degree.grantor The University of Alabama
etdms.degree.level doctoral
etdms.degree.name Ph.D.


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