Investigations sur les déviations expérimentales géométriques du procédé 3DP-LPBF

Abstract

This project applies in the field of additive manufacturing (FA). More exactly, it aims of the identification of Laser Powder Bed Fusion (LPBF), or selective laser melting process (3DPLPBF) performances. Within the framework of the present project, we are interested in the shrinkage and in the dimensional and geometrical variations, which intervenes on parts stemming from this process. LPBF processes are relatively young, and because of a lack of data, there is only small amount of information or standards, which address the process capability. The knowledge of the dimensional performances of the process LPBF is essential in a ‘Design for Manufacturing’ process. This project propose to study and quantify them. The first step of this research project consists of quantifying the parts position on the manufacturing chamber effect on the geometrical and dimensional deviations. The aim of the approach is to detect a deviation distribution pattern in the chamber and propose a positioning guide to the designers. The first step also consists of quantifying the process inter (from one impression to another) and intra (identical components in the same impression) repeatability. This step has been the subject of a first publication in a peer-reviewed journal. « Intra- and Inter-Repeatability of Profile Deviations of an AlSi10Mg Tooling Component Manufactured by Laser Powder Bed Fusion » Journal of Manufacturing and Materials Processing, 2018, 2(3), 56-70. The second step consisted of quantifying the material repartition effect, along with the scale effect on the dimensional and geometrical deviations of the parts. This step also consisted on quantifying the process post-treatment steps effects on the printed distortions, which are the stress-relieving heat treatment, the part removal from the build plate, and the shot peening. This step has been the subject of a second publication in a peer-reviewed journal. « Scale, Material Concentration, Stress Relief and Part Removal Effects on the Dimensional Behaviour of Selected AlSi10Mg Components Manufactured by Laser Powder Bed Fusion », Journal of Manufacturing and Materials Processing, 2019, 3(2), 49-67. With the arrival of ANSYS Additive (by ANSYS incorporation) , which one of the functionalities is to predict the geometrical deviations of LPBF, we found interesting to validate its performances through numerically predicted and experimentally measured distortions comparison of artifacts designed and printed for the case study. This step has been the subject of an oral presentation at the HI AM conference, and a publication in a peer-reviewed journal. « Geometric deviations of laser powder bed fused AlSi10Mg components: Numerical Predictions versus Experimental Measurements » Additive Manufacturing Journal, submitted article. The fourth step of this study consists on successively implement the quantified effect on a model to predict LPBF parts dimensional deviations. The model is based on metrics that estimate the dimensional deviations based on the material repartition (or concentration), which implicitly takes in account the scale effect. We present the results of the model and compare its performance with other numerical simulations and experimental measurements.

Date	19 Dec 2019
Original language	French
Awarding Institution	École de technologie supérieure
Supervisor	Antoine Tahan (Supervisor) & Vladimir Brailovski (Co-supervisor)