Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study

Sankhya Mohanty; Jesper Henri Hattel

doi:10.1117/12.2253600

24 February 2017 Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study

Sankhya Mohanty, Jesper Henri Hattel

Proceedings Volume 10095, Laser 3D Manufacturing IV; 100950G (2017) https://doi.org/10.1117/12.2253600
Event: SPIE LASE, 2017, San Francisco, California, United States

Abstract

Selective laser melting is fast evolving into an industrially applicable manufacturing process. While components produced from high-value materials, such as Ti6Al4V and Inconel 718 alloys, are already being produced, the processing of multi-material components still remains to be achieved by using laser additive manufacturing. The physical handling of multi-material in a SLM setup continues to be a primary challenge along with the selection of process parameters/plan to achieve the desired results – both challenges requiring considerable experimental undertakings. Consequently, numerical process modelling has been adopted towards tackling the latter challenge in an effective manner. In this paper, a numerical simulation based optimization study is undertaken to enable selective laser melting of multi-material tool inserts. A standard copper specimen covered by a thin layer of nickel is chosen, over which a layer of steel has been deposited using cold-spraying technique, such as to protect the microstructure of Ni during selective laser melting. The process modelled thus entails additively manufacturing a steel tool insert around the multi-material specimen with a goal of achieving a dense product while preventing recrystallization in the Nickel layer. The process is simulated using a high-fidelity thermo-microstructural model with constant processing parameters to capture the effect on Nickel layer. Based on results, key structural and process parameters are identified, and subsequently an optimization study is conducted using evolutionary algorithms to determine the appropriate process parameter values as well as processing sequence. The optimized process plan is then used to manufacture real multi-material tool insert samples by selective laser melting.

Citation Download Citation

Sankhya Mohanty and Jesper Henri Hattel "Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study", Proc. SPIE 10095, Laser 3D Manufacturing IV, 100950G (24 February 2017); https://doi.org/10.1117/12.2253600

ACCESS THE FULL ARTICLE

INSTITUTIONAL
Select your institution to access the SPIE Digital Library.

SELECT YOUR INSTITUTION

PERSONAL
Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.

PERSONAL SIGN IN

No SPIE Account? Create one

PURCHASE THIS CONTENT

SUBSCRIBE TO DIGITAL LIBRARY

50 downloads per 1-year subscription

Members: $195

Non-members: $335 ADD TO CART

25 downloads per 1 - year subscription

Members: $145

Non-members: $250 ADD TO CART

PURCHASE SINGLE ARTICLE

Includes PDF, HTML & Video, when available