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Simulations of Thermo-Mechanical Characteristics in Electron Beam Additive Manufacturing

[+] Author Affiliations
Ninggang Shen, Kevin Chou

The University of Alabama, Tuscaloosa, AL

Paper No. IMECE2012-88476, pp. 67-74; 8 pages
  • ASME 2012 International Mechanical Engineering Congress and Exposition
  • Volume 3: Design, Materials and Manufacturing, Parts A, B, and C
  • Houston, Texas, USA, November 9–15, 2012
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-4519-6
  • Copyright © 2012 by ASME


In the direct digital metal manufacturing, Electron Beam Additive Manufacturing (EBAM) has been used to fabricate sophisticated metallic parts, in a layer by layer fashion, by sintering and/or melting metal powders. In principle, EBAM utilizes a high-energy electron beam to melt and fuse metal powders to build solid parts with various materials, such as Ti-6Al-4V which is very difficult to fabricate using conventional processes. EBAM is one of a few Additive Manufacturing (AM) technologies capable of making full-density metallic parts and has drastically extended AM applications.

The heat transfer analysis has been conducted in a simple case of a single-scan path with the effect of powder porosity investigated. In the actual EBAM process, the scan pattern is typically alternate raster. In this study, a coupled thermo-mechanical finite element model was developed to simulate the transient heat transfer, part residual stresses of alternate raster during the EBAM process subject to a moving heat source with a Gaussian volumetric distribution. The developed model was first examined against literature data. The coupled mechanical simulation is able to capture the evolution of the part residual stresses in EBAM.

Copyright © 2012 by ASME



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