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Voxel-based full-field eigenstrain reconstruction of residual stresses in additive manufacturing parts using height digital image correlation

Abstract:

The formation of residual stresses is inevitable during the additive manufacturing of metallic parts due to thermo-mechanicals effects, but the chaotic nature of printing processes makes it impossible to have a comprehensive understanding about the magnitude and distribution of these residuals. The voxel-based eigenstrain (inherent strain) reconstruction method is capable of the full-field reconstruction of residual stresses in discontinuous processing bodies at a scale that depends on the resolution of experimental data without using simplifying assumptions and regularisation functions. This advanced method firstly maps the distribution of eigenstrains and then quantifies corresponding residual stresses, residual elastic strains, and displacements by a cost-effective linear elastic computational framework. The reliability of this process solely depends on the quality of experimental data and the availability of computational power. The motivation behind this study is the use of the voxel-based eigenstrain reconstruction method for the full-field mapping of complex residual stress fields, that cannot be predicted by regularizing assumptions, in discontinuous processing additive manufacturing parts. The height Digital Image Correlation (hDIC) technique satisfied the need for high-quality experimental data by calculating triaxial displacements, corresponding to the elastic response of CM 247 LC powder bed fusion (PBF) additive manufacturing part after changes in the boundary conditions due to separation from the base, using optical profilometry measurements at a resolution adjusted in a way to reconstruct Type I residual stresses. Three components of displacements calculated by the hDIC were used to map the distribution of three components of eigenstrains for the reconstruction of six residual stress, six residual elastic strain and three displacement components that belong to the before and after separating from the base states. The reliability of calculations has been validated by monochromatic synchrotron X-ray beams in powder diffraction mode from the same surface of optical profilometry measurements and in transmission mode from the sampling volumes.

Publications: 

  1. Fatih Uzun, Hector Basoalto, Konstantinos Liogas, Jingwei Chen, Igor P. Dolbnya, Zifan Ivan Wang, Alexander M. Korsunsky, Voxel-based full-field eigenstrain reconstruction of residual stresses in additive manufacturing parts using height digital image correlation, Additive Manufacturing, Volume 77, 5 September 2023, 103822.

  2. Y. Lu, R. Turner, B. Cai, C. Fang, F. Wang, Y-L Chiu, J. Brooks, H. Basoalto, Microstructural, Mechanical and In-Situ Evaluations of Electron Beam Welded Ti-6al-4v Alloy after Post-Weld Heat Treatments, 2023.

  3. M.J. Anderson and H. C. Basoalto, Automated Stereology and Uncertainty Quantification Considering Spherical Non-Penetrating Dispersions, Crystals 2023, 13(3), 464.

  4. F. M. Muller, C. Fang, H. C. Basoalto, S. Williams, P. Bowen, Modelling and predictions of time-dependent local stress distributions around cracks under dwell loading in a nickel-based superalloy at high temperatures, International Journal of Fatigue, Volume 163, October 2022, 107038.

  5. C.Z. Fang, H.C. Basoalto, M.J. Anderson, H.Y. Li, S.J. Williams, P. Bowen, A numerical study on the influence of grain boundary oxides on dwell fatigue crack growth of a nickel-based superalloy, Journal of Materials Science & Technology 104 (2022) 224–235.

  6. Y. Lu, R. Turner, J. Brooks, H Basoalto, A study of process-induced grain structures during steady state and non-steady state electron-beam welding of a titanium alloy, Journal of Materials Science & Technology 113 (2022) 117–127.

  7. Y. Lu, R. Turner, J. Brooks, H. Basoalto, Microstructural characteristics and computational investigation on electron beam welded Ti-6Al-4 V alloy, Journal of Materials Processing Technology, Volume 288, 2021, 116837.

  8. L Stanger, T. Rockett, A. Lyle, M. Davies, M. Anderson, I. Todd ,H. Basoalto, J.R. Willmott, Reconstruction of Microscopic Thermal Fields from oversampled Infrared Images in Laser-Based Powder Bed Fusion, Sensors 2021, 21, 4859.

  9. S. Afazov, A Roberts, L. Wright, Prashant Jadhav, A. Holloway, H. Basoalto, K. Milne, N. Brierley, Metal powder bed fusion process chains: an overview of modelling techniques, Prog Addit Manuf 7, 289–314 (2022).

  10. Y. Lu, M. Wang, Z. Wu, I. P. Jones, M. Wickins, H. C. Basoalto, N. R. Green, Three-dimensional analysis of dendrites via automated serial sectioning using a Robo-Met.3D, RS Communications 10, 461–466 (2020).

  11. V.L. Jantara Juniora, H. Basoalto, M. Papaeliasa, A damage mechanics approach for lifetime estimation of wind turbine gearbox materials, Int J Fatigue, Volume 137, August 2020, 105671.

  12. Thomas F. Flint, L. Scotti, H. C. Basoalto, M. C. Smith, A thermal fluid dynamics framework applied to multi-component substrates experiencing fusion and vaporisation state transitions, COMMUNICATIONS PHYSICS | (2020) 3:196 .

  13. M.J. Anderson, F. Schulz, Y. Lu, H.S. Kitaguchi, P. Bowen, C. Argyrakis, H.C. Basoalto, On the modelling of precipitation kinetics in a turbine disc nickel-based superalloy, Acta Materialia 191 (2020) 81100

  14. M J. Anderson, J Benson, J W. Brooks, B Saunders, H C. Basoalto, Predicting precipitation kinetics during the annealing of additive manufactured Inconel 625 components, JOM, 2019.

  15. Hector C. Basoalto, C. Panwisawas, Y. Sovani, M. J. Anderson, R. P. Turner, B. Saunders, J. W. Brook, A computational study on the three-dimensional printability of precipitate-strengthened nickel-based superalloy, Proceedings of the Royal Society A, 2018.

  16. Magnus J. Anderson, Chinnapat Panwisawas, Yogesh Sovani, Richard P. Turner, Jeffery W. Brooks, Hector C. Basoalto, Mean-field modelling of the intermetallic precipitate phases during heat treatment and additive manufacture of Inconel 718, Acta Materialia 156 (2018) 432-445

  17. R.P. Turner, C. Panwisawas, Y. Lu, I. Dhiman, H.C. Basoalto, J.W. Brooks, Neutron tomography methods applied to a nickel-based superalloy additive manufacture build, Materials Letters 230 (2018) 109–112.

  18. T.F. Flint, C. Panwisawas, Y. Sovani, M.C. Smith, H.C. Basoalto, Prediction of grain structure evolution during rapid solidification of high energy density beam induced re-melting, Materials and Design 147 (2018) 200–210.

  19. Chinnapat Panwisawas, Yogesh Sovani, Richard P. Turner, Jeffery W. Brooks, Hector C. Basoalto, Isabelle Choquet, Modelling of thermal fluid dynamics for fusion welding, Journal of Materials Processing Tech. 252 (2018) 176–182.

  20. Chinnapat Panwisawas, Chunlei Qiu, Magnus J Anderson, Yogesh Sovani, Richard P Turner, Moataz M Attallah, Jeffery W Brooks, Hector C Basoalto, Mesoscale modelling of selective laser melting: Thermal fluid dynamics and microstructural evolution, Comput. Mater. Sci, 126 (2017) 479-490.

  21. Hector Basoalto and Magnus Anderson, An extension of mean-field coarsening theory to include particle coalescence using nearest-neighbour functions, Acta Materialia 117 (2016) 122-134.

  22. Richard P. Turner, Chinnapat Panwisawas, Yogesh Sovani, Bama Perumal, R. Mark Ward, Jeffery W. Brooks, Hector C. Basoalto, An Integrated Modeling Approach for Predicting Process Maps of Residual Stress and Distortion in a Laser Weld: A Combined CFD–FE Methodology, Metallurgical And Materials Transactions B, October 2016, Volume 47, Issue 5, pp 2954–2962

  23. M.J. Anderson, A. Rowe, J. Wells, H.C. Basoalto, Application of a multi-component mean field model to the coarsening behaviour of a nickel-based superalloy, Acta Materialia 114 (2016) 80-96.

  24. R.P. Turner, D. Howe, B. Thota, R.M. Ward, H.C. Basoalto, J.W. Brooks, Calculating the energy required to undergo the conditioning phase of a titanium alloy inertia friction weld, Journal of Manufacturing Processes, 24 (2016) 186-194.

  25. R.P. Turner, M. Villa, Y. Sovani, C. Panwisawas, B. Perumal, R.M. Ward, J.W. Brooks, And H.C. Basoalto, An Improved Method of Capturing the Surface Boundary of a Ti-6Al-4V Fusion Weld Bead for Finite Element Modeling, Metallurgical And Materials Transactions B, 2015

  26. Panwisawas,C., Qiu, C., Sovani, Y., Brooks, J.W., Attallah, M., Basoalto, H.C., On the role of thermal fluid dynamics into the evolution of porosity during selective laser melting, (2015) Scripta Materialia 105:14-17.

  27. Qiu, C.,Panwisawas, C. , Ward, M., Basoalto, H.C., Brooks, J.W., Attallah, M.A. (2015), On the role of melt flow into the surface structure and porosity development during selective laser melting, Acta Materialia 96:72-79.

  28. Zhu, Z., Basoalto, H.C.,  Warnken, N., Reed, RC  (2012), A Model For The Creep Deformation Behaviour Of Nickel-Based Single Crystal Superalloys , Volume 60, Issue 12, Pages 4888–4900.

  29. Coakley, J., Dye, D. And Basoalto, H.C (2011), Creep and creep modelling of a multimodal nickel-base superalloy, Acta Materialia 59,  854–863.

  30. Basoalto, H.C, Sondhi, S.K., Dyson, B.F., And Mclean (2004), A Generic Microstructure-Explicit Model of Creep in Nickel-Based Superalloys, in Superalloys 2004, eds. Pollock, T.M. et al., p. 897-906.

  31. Coakley, J., Basoalto, H.C, And Dye, D., Coarsening of a Multi-Modal Nickel-Base Superalloy, Acta Materialia, Acta Materialia 58 (2010) 4019.

  32. Brooks, J.W., Basoalto, H.C., Sahota, R., And Tranter, P., Probabilistic Property Prediction Of Aero-Engine Components For Fatigue, Vol 6: Structures and Dynamics, Parts A and B, ASME Conference Proceedings, 2010.

  33. Basoalto, H.C., J.W. Brooks And Di Martino, I., Multi-Scale Microstructure Modelling for Nickel-Based Superalloys, Journal Materials Science and Technology , Vol. 25, No. 2, pp 221-227, 2009.

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