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Experimental Investigation and Numerical Simulation of Residual Stress and Distortion of Ti6Al4V Components Manufactured Using Selective Laser Melting

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Abstract

Residual stress and distortion are inevitable during metal selective laser melting (SLM) process due to the high thermal gradient. Based on an experimental investigation and a numerical simulation, this paper studied the effect of geometric size and structural feature on the residual stress and distortion of hollow Ti-alloy blades fabricated using SLM. The results indicated that the distortion of blades increased with the increase in height and torsion angle of the blades. However, distortion obviously decreased when the stiffened plates were set inside the blades and the blade thickness increased. When the number of stiffened plates increased from zero to three and the blade thickness increased from 0.5 to 2 mm, the distortion value was reduced by the biggest rate of 38 and 35%, respectively. In addition, the residual stress along the building direction was found to play a dominant role in inducing the distortion. This study showed a new viewpoint to reduce the distortion by optimizing the geometric size and structural feature of a metal part.

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Acknowledgments

This work was supported by the Shanghai Sailing Program [19YF1417500] and Open Project of State Key Laboratory of Advanced Special Steel, Shanghai Key Laboratory of Advanced Ferrometallurgy, Shanghai University (SKLASS2020-10) and the Science and Technology Commission of Shanghai Municipality (No. 19DZ2270200)

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Authors and Affiliations

  1. Research center of High-Temperature Alloy Precision Forming, School of Materials Engineering, Shanghai University of Engineering Science, Shanghai, 201620, China

    Shuang Gao, Zhijun Tan, Liang Lan & Bo He

  2. State Key Laboratory of Advanced Special Steels, School of Materials Science and Engineering, Shanghai University, Shanghai, 200444, China

    Shuang Gao

  3. Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials, Ministry of Education, School of Materials Science and Engineering, Shandong University, Jinan, 250061, Shandong, China

    Guoxin Lu

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  1. Shuang Gao
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Contributions

Shuang Gao*: Conceptualization, Methodology, Resources, Writing - review & editing, Supervision. Zhijun Tan: Conceptualization, Methodology, Validation, Formal analysis, Investigation, Data curation, Writing - original draft. Zhenfeng Song: Conceptualization, Formal analysis. Liang Lan: Conceptualization, Formal analysis. Bo He*: Conceptualization, Formal analysis, Project administration, Funding acquisition.

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Correspondence to Shuang Gao or Bo He.

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Gao, S., Tan, Z., Lan, L. et al. Experimental Investigation and Numerical Simulation of Residual Stress and Distortion of Ti6Al4V Components Manufactured Using Selective Laser Melting. J. of Materi Eng and Perform 31, 8113–8123 (2022). https://doi.org/10.1007/s11665-022-06815-3

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