Overview:

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Laser Metal Deposition (LMD) using wire-based processing is renowned for its high deposition rates and suitability for large-scale manufacturing. However, these advantages come with challenges such as residual stress and cracking.

 

Project Funding and Collaboration

 

This study, funded by ATI(DAM), collaborates with GKN as the industrial partner. The aim is to introduce a multi-scale process model that connects process variables to microstructure and material properties. This model will support certification and lifing methods for additively manufactured components.

 

Methodology:

 

The approach incorporates accurate thermal field representation using Finite Element Analysis (FEA). This is followed by models for grain growth and phase transitions, employing Cellular Automaton and JMAK (Johnson-Mehl-Avrami-Kolmogorov) methodologies.

 

Outcomes:

 

This multi-scale model facilitates the generation of realistic microstructures and allows for the implementation of location-specific predictions of mechanical behaviour, ultimately enhancing the understanding and reliability of components produced through LMD.