@article{SprengelMohrAltenburgetal.2021, author = {Sprengel, Maximilian and Mohr, Gunther and Altenburg, Simon J. and Evans, Alexander and Serrano-Munoz, Itziar and Kromm, Arne and Pirling, Thilo and Bruno, Giovanni and Kannengießer, Thomas}, title = {Triaxial residual stress in Laser Powder Bed Fused 316L}, series = {Advanced engineering materials}, volume = {24}, journal = {Advanced engineering materials}, number = {6}, publisher = {Wiley-VCH}, address = {Weinheim}, issn = {1438-1656}, doi = {10.1002/adem.202101330}, pages = {13}, year = {2021}, abstract = {The control of residual stress (RS) remains a challenge in the manufacturing of metallic parts using the laser powder bed fusion process (LPBF). This layer-by-layer manufacturing approach gives rise to complex triaxial RS distributions, which require extensive characterization effort for a broader acceptance of LPBF in industry. This study focuses on the distribution of bulk triaxial RS and surface RS in LPBF austenitic steel 316L. The RS are determined by X-ray and neutron diffraction to characterize the RS distribution. Variations in the LPBF parameters interlayer time (ILT) and scanning velocity and their influence on the temperature distribution and resulting RS is investigated using thermographic data from in situ process monitoring. The RS in the LPBF 316L is tensile at the surface and compressive in the bulk. The RS is directly related to the thermal history of the part as shown by the in situ thermography data. Shorter ILT leads to higher temperatures of the part during the manufacturing, which decrease the RS and RS formation mechanisms. Interestingly, the surface RS does not agree with this observation. This study highlights the benefit of using multiple RS determination methods and in situ thermography monitoring to characterize the RS in LPBF processed parts.}, language = {en} } @article{SerranoMunozMishurovaThiedeetal.2020, author = {Serrano-Munoz, Itziar and Mishurova, Tatiana and Thiede, Tobias and Sprengel, Maximilian and Kromm, Arne and Nadammal, Naresh and Nolze, Gert and Saliwan-Neumann, Romeo and Evans, Alexander and Bruno, Giovanni}, title = {The residual stress in as-built laser powder bed fusion IN718 alloy as a consequence of the scanning strategy induced microstructure}, series = {Scientific reports}, volume = {10}, journal = {Scientific reports}, number = {1}, publisher = {Macmillan Publishers Limited, part of Springer Nature}, address = {London}, issn = {2045-2322}, doi = {10.1038/s41598-020-71112-9}, pages = {15}, year = {2020}, abstract = {The effect of two types of scanning strategies on the grain structure and build-up of Residual Stress (RS) has been investigated in an as-built IN718 alloy produced by Laser Powder Bed Fusion (LPBF). The RS state has been investigated by X-ray diffraction techniques. The microstructural characterization was performed principally by Electron Backscatter Diffraction (EBSD), where the application of a post-measurement refinement technique enables small misorientations (< 2 degrees) to be resolved. Kernel average misorientation (KAM) distributions indicate that preferably oriented columnar grains contain higher levels of misorientation, when compared to elongated grains with lower texture. The KAM distributions combined with X-ray diffraction stress maps infer that the increased misorientation is induced via plastic deformation driven by the thermal stresses, acting to self-relieve stress. The possibility of obtaining lower RS states in the build direction as a consequence of the influence of the microstructure should be considered when envisaging scanning strategies aimed at the mitigation of RS.}, language = {en} } @article{FritschSprengelEvansetal.2021, author = {Fritsch, Tobias and Sprengel, Maximilian and Evans, Alexander and Farahbod-Sternahl, Lena and Saliwan-Neumann, Romeo and Hofmann, Michael and Bruno, Giovanni}, title = {On the determination of residual stresses in additively manufactured lattice structures}, series = {Journal of applied crystallography / International Union of Crystallography}, volume = {54}, journal = {Journal of applied crystallography / International Union of Crystallography}, publisher = {Munksgaard}, address = {Copenhagen}, issn = {0021-8898}, doi = {10.1107/S1600576720015344}, pages = {228 -- 236}, year = {2021}, abstract = {The determination of residual stresses becomes more complicated with increasing complexity of the structures investigated. Additive manufacturing techniques generally allow the production of 'lattice structures' without any additional manufacturing step. These lattice structures consist of thin struts and are thus susceptible to internal stress-induced distortion and even cracks. In most cases, internal stresses remain locked in the structures as residual stress. The determination of the residual stress in lattice structures through nondestructive neutron diffraction is described in this work. It is shown how two difficulties can be overcome: (a) the correct alignment of the lattice structures within the neutron beam and (b) the correct determination of the residual stress field in a representative part of the structure. The magnitude and the direction of residual stress are discussed. The residual stress in the strut was found to be uniaxial and to follow the orientation of the strut, while the residual stress in the knots was more hydrostatic. Additionally, it is shown that strain measurements in at least seven independent directions are necessary for the estimation of the principal stress directions. The measurement directions should be chosen according to the sample geometry and an informed choice on the possible strain field. If the most prominent direction is not measured, the error in the calculated stress magnitude increases considerably.}, language = {en} } @article{SchroederEvansMishurovaetal.2021, author = {Schr{\"o}der, Jakob and Evans, Alexander and Mishurova, Tatiana and Ulbricht, Alexander and Sprengel, Maximilian and Serrano-Munoz, Itziar and Fritsch, Tobias and Kromm, Arne and Kannengießer, Thomas and Bruno, Giovanni}, title = {Diffraction-based residual stress characterization in laser additive manufacturing of metals}, series = {Metals : open access journal}, volume = {11}, journal = {Metals : open access journal}, number = {11}, publisher = {MDPI}, address = {Basel}, issn = {2075-4701}, doi = {10.3390/met11111830}, pages = {34}, year = {2021}, abstract = {Laser-based additive manufacturing methods allow the production of complex metal structures within a single manufacturing step. However, the localized heat input and the layer-wise manufacturing manner give rise to large thermal gradients. Therefore, large internal stress (IS) during the process (and consequently residual stress (RS) at the end of production) is generated within the parts. This IS or RS can either lead to distortion or cracking during fabrication or in-service part failure, respectively. With this in view, the knowledge on the magnitude and spatial distribution of RS is important to develop strategies for its mitigation. Specifically, diffraction-based methods allow the spatial resolved determination of RS in a non-destructive fashion. In this review, common diffraction-based methods to determine RS in laser-based additive manufactured parts are presented. In fact, the unique microstructures and textures associated to laser-based additive manufacturing processes pose metrological challenges. Based on the literature review, it is recommended to (a) use mechanically relaxed samples measured in several orientations as appropriate strain-free lattice spacing, instead of powder, (b) consider that an appropriate grain-interaction model to calculate diffraction-elastic constants is both material- and texture-dependent and may differ from the conventionally manufactured variant. Further metrological challenges are critically reviewed and future demands in this research field are discussed.}, language = {en} }