During layered manufacturing of functional metallic parts by laser direct metal deposition (LDMD) residual stresses are generated by the transient thermal fields. Various methods to reduce or control the development of these stresses have been previously attempted. This paper reports a novel method using the pulse parameters of a diode laser deposition system as a tool for residual stress control. Stresses in LDMD manufactured Waspaloy blocks are calculated from strain measurements in three directions carried out at the neutron diffraction beam line SALSA at the European ILL facility, Grenoble, France. The results show tensile stresses close to the top of the structures of similar magnitude for all parameters and large compressive stresses normal to the deposition surface close to the base.
REFERENCES
1.
D.T.
Pham
and R. S.
Gault
, A comparison of rapid prototyping technologies
. International journal of machine tools and manufacture
, 1998
. 38
: 1257
–1287
.2.
Y.
Zhang
and L.
Shi
, Research on Laser Direct Metal Deposition
. First International Symposium on High-Power Laser Macro processing
, Proceedings of SPIE, 2003
. 4831
: 487
–482
.3.
L.
Sexton
, S.
Lavin
, G.
Byrne
, and A.
Kennedy
, Laser cladding of aerospace materials
. Journal of Materials Processing Technology
, 2002
. 122
: 63
–68
.4.
W.
Ul Haq Syed
, A.J.
Pinkerton
, and L.
Li
, A comparative study of wire feeding and powder feeding in direct diode laser deposition for rapid prototyping
. Applied Surface Science
, 2005
. 247
: 268
–276
5.
L.
Peng
, Direct laser fabrication of nickel alloy samples
. International Journal of Machine Tools & Manufacture
, 2005
. 45
: 1288
–1294
.6.
A.J.
Pinkerton
, M.
Karadge
, W.
ul Haq Syed
, and L.
Li
, Thermal and Microstructural Aspects of the Laser Direct Metal Deposition of Waspaloy
. Journal of Laser Applications
, 2006
. 18
: 216
–225
.7.
A.J.
Pinkerton
, R.J.
Moat
, L.
Li
, M.
Preuss
, and P.J.
Withers
. Diode Laser Metal Deposition: The Effect of Pulsed Beam Parameters on Superalloy Microstructure and Deposit Morphology
. in ICALEO
. 2006
. Florida
.8.
P.J.
Withers
, Residual Stress: Definition
. Encyclopaedia of Materials: Science and Technology
, 2006
: 8110
–8112
.9.
T.W.
Clyne
and Y.C.
Tsui
, An analytical model for predicting residual stresses in progressively deposited coatings Part 1: Planar geometries
. Thin Solid Films
, 1997
. 306
: 23
–35
.10.
P.
Rangaswamy
, T. M.
Holden
, R. B.
Rogge
, and M. L. Griffith, Residual stresses in components formed by the laser engineered net shaping (LENS) process
. J. Strain Analysis
, 2003
. 38
(6
): 219
–226
.11.
M.L.
Griffith
, Understanding thermal behaviour in the LENS process
. Materials and Design
, 1999
. 20
: 107
–113
.12.
S.
Finnie
, W.
Cheng
, I.
Finnie
, J.M.
Drezet
, and M.
Gremaud
, The computation and measurement of residual stresses in laser deposited layers
. Journal of Engineering Materials and Technology
, Transactions of the ASME, 2003
. 125
(3
): 302
–308
.13.
P.
Rangaswamy
, M. L.
Griffith
, and M.B.
Prime
, Residual stresses in LENS® components using neutron diffraction and contour method
. Materials Science and Engineering A
, 2005
. 399
: 72
–83
.14.
J.
Beuth
and N.
Lingbeil
, The role of process variables in laser-based direct metal solid freeform fabrication
. Journal of Materials
, 2001
. 53
(9
): 36
–39
.15.
R.K.
Chin
, J.L.
Beuth
, and C.H.
Amon
, Thermomechanical modelling of molten metal droplet solidification applied to layered manufacturing
. Mechanics of Materials
, 1996
. 24
(4
): 257
–271
.16.
Y.Z.
Zhang
, L.K.
Shi
, P.Z.
Zhang
, M.Z.
Xi
, and J.
Cheng
, Research on laser direct deposition of nickel base superalloy
. Journal of Aeronautical Materials
, 2002
. 22
(1
): 22
–25
.17.
N.
Klingbeil
, J.L.
Beuth
, R.K.
Chin
, and C.H.
Amon
, Measurement and modelling of residual stress-induced warping in direct metal deposition processes
. Journal of Materials Science
, 2002
. 44
(1
): 57
–77
.18.
A.J.
Pinkerton
, J.
Shackleton
, R.
Moat
, L.
Li
, P.J.
Withers
, M.
Preuss
, J.
Allen
, P.
Hilton
, and R.
Folwell
. The effect of process parameters on residual stresses within an IN718 part produced by the direct laser deposition process
. in ICALEO
. 2005
. Florida
.19.
P.J.
Withers
, Residual Stresses: Measurement by Diffraction
. Encyclopaedia of Materials: Science and Technology
, 2006
: 8158
–8169
.20.
A.
Steuwer
, J.R.
Santisteban
, M.
Turski
, P.J.
Withers
, and T.
Buslaps
, High-Resolution strain mapping in bulk samples using full-profile analysis of energy dispersive synchrotron X-ray diffraction data
. Nuclear Instruments and Methods in Physics Research B
, 2005
. 238
: 200
–204
.21.
G.S.
Schajer
, Residual Stresses: Measurement by Destructive Testing
. Encyclopaedia of Materials: Science and Technology
, 2006
: 8152
–8158
.22.
M.B.
Prime
, Cross-sectional mapping of residual stress by measuring the surface contours after a cut
. Journal of Materials Engineering and Technology
, 2001
. 123
: 162
–168
.23.
T.
Pirling
, G.
Bruno
, and P.J.
Withers
, SALSA - A new instrument for strain imaging in engineering materials and Components
. Materials Science and Engineering A
, 2006
. 437
: 139
–144
.24.
D.
Dye
, H.J.
Stone
, and R.C.
Reed
, A Two Phase Elastic-Plastic Self-Consistent Model for the Accumulation of Microstrain in Waspaloy
. Acta Materialia
, 2000
. 49
: 1271
–1283
.25.
R.J.
Moat
, M.
Karadge
, A.J.
Pinkerton
, A.
Deschamps
, F.
Bley
, L.
Li
, P.J.
Withers
, and M.
Preuss
. Intragranular Precipitation Variations in Laser Deposited Wasplaoy due to Compositional Inhomogeneities
. In precedings of the TMS annual meeting
. 2006
. Orlando, USA
.26.
K
Chang
and X
Liu
, Effect of gamma prime content on the mechanical behaviour of the WASPALOY alloy system
. Materials Science and Engineering
, 2001
. A308
: 1
–8
.
This content is only available via PDF.
© 2007 Laser Institute of America.
2007
Laser Institute of America
You do not currently have access to this content.