Hydrogen production for energy: An overview

DAMASK – The Düsseldorf Advanced Material Simulation Kit for modeling multi-physics crystal plasticity, thermal, and damage phenomena from the single crystal up to the component scale

Metal additive manufacturing (AM) has garnered tremendous research and industrial interest in recent years; in the field, powder bed fusion (PBF) processing is the most common technique, with selective laser melting (SLM) dominating the landscape followed by electron beam melting (EBM). Through continued process improvements, these methods are now often capable of producing high strength parts with static strengths exceeding their conventionally manufactured counterparts. However, PBF processing also results in large and anisotropic residual stresses (RS) that can severely affect fatigue properties and result in geometric distortion. The dependence of RS formation on processing variables, material properties and part geometry has made it difficult to predict efficiently and has hindered widespread acceptance of AM techniques. Substantial investigations have been conducted with regards to RS in PBF processing, which have illuminated a number of important relationships, yet a review encompassing this information has not been available. In this review, we survey and assemble the knowledge existing in the literature regarding RS in PBF processes. A discussion of background mechanics for RS development in AM is provided along with methods of measurement, highlighting the anisotropic nature of the stress fields. We then review modeling efforts and in-process experimental measurements made to advance process understanding, followed by a thorough analysis and summary of the known relationships of both material properties and processing variables to resulting RS. The current state of knowledge and future research needs for the field are discussed.

An overview of residual stresses in metal powder bed fusion

Mechanistic models for additive manufacturing of metallic components

Additive manufacturing of industrially-relevant high-performance parts and products is today a reality, especially for metal additive manufacturing technologies. The design complexity that is now possible makes it particularly useful to improve product performance in a variety of applications. Metal additive manufacturing is especially well matured and is being used for production of end-use mission-critical parts. The next level of this development includes the use of intentionally designed porous metals - architected cellular or lattice structures. Cellular structures can be designed or tailored for specific mechanical or other performance characteristics and have numerous advantages due to their large surface area, low mass, regular repeated structure and open interconnected pore spaces. This is considered particularly useful for medical implants and for lightweight automotive and aerospace components, which are the main industry drivers at present. Architected cellular structures behave similar to open cell foams, which have found many other industrial applications to date, such as sandwich panels for impact absorption, radiators for thermal management, filters or catalyst materials, sound insulation, amongst others. The advantage of additively manufactured cellular structures is the precise control of the micro-architecture which becomes possible. The huge potential of these porous architected cellular materials manufactured by additive manufacturing is currently limited by concerns over their structural integrity. This is a valid concern, when considering the complexity of the manufacturing process, and the only recent maturation of metal additive manufacturing technologies. Many potential manufacturing errors can occur, which have so far resulted in a widely disparate set of results in the literature for these types of structures, with especially poor fatigue properties often found. These have improved over the years, matching the maturation and improvement of the metal additive manufacturing processes. As the causes of errors and effects of these on mechanical properties are now better understood, many of the underlying issues can be removed or mitigated. This makes additively manufactured cellular structures a highly valid option for disruptive new and improved industrial products. This review paper discusses the progress to date in the improvement of the fatigue performance of cellular structures manufactured by additive manufacturing, especially metal-based, providing insights and a glimpse to the future for fatigue-tolerant additively manufactured architected cellular materials.

Architected cellular materials: A review on their mechanical properties towards fatigue-tolerant design and fabrication

From microstructural design to surface engineering: A tailored approach for improving fatigue life of additively manufactured meta-biomaterials.

A small strain two-dimensional discrete dislocation plasticity framework coupled to vacancy diffusion is developed wherein the motion of edge dislocations is by a combination of glide and climb. The dislocations are modelled as line defects in a linear elastic medium and the mechanical boundary value problem is solved by the superposition of the infinite medium elastic fields of the dislocations and a complimentary non-singular solution that enforces the boundary conditions. Similarly, the climbing dislocations are modelled as line sources/sinks of vacancies and the vacancy diffusion boundary value problem is also solved by a superposition of the fields of the line sources/sinks in an infinite medium and a complementary non-singular solution that enforces the boundary conditions. The vacancy concentration field along with the stress field provides the climb rate of the dislocations. Other short-range interactions of the dislocations are incorporated via a set of constitutive rules. We first employ this formulation to investigate the climb of a single edge dislocation in an infinite medium and illustrate the existence of diffusion-limited and sink-limited climb regimes. Next, results are presented for the pure bending and uniaxial tension of single crystals oriented for single slip. These calculations show that plasticity size effects are reduced when dislocation climb is permitted. Finally, we contrast predictions of this coupled framework with an ad hoc model in which dislocation climb is modelled by a drag-type relation based on a quasi steady-state solution.

Climb-enabled discrete dislocation plasticity

Selective laser melting (SLM) wherein a metal part is built in a layer-by-layer manner in a powder bed is a promising and versatile way for manufacturing components with complex geometry. However, components built by SLM suffer from substantial deformation of the part and residual stresses. Residual stresses arise due to temperature gradients inherent to the process and the accompanying deformation. It is well known that the SLM process parameters and the laser scanning strategy have a substantial effect on the temperature transients of the part and henceforth on the degree of deformations and residual stresses. In order to provide a tool to investigate this relation, a semi-analytical thermal model of the SLM process is presented which determines the temperature evolution in a 3D part by way of representing the moving laser spot with a finite number of point heat sources. The solution of the thermal problem is constructed from the superposition of analytical solutions for point sources which are known in semi-infinite space and complimentary numerical/analytical fields to impose the boundary conditions. The unique property of the formulation is that numerical discretisation of the problem domain is decoupled from the steep gradients in the temperature field associated with localised laser heat input. This enables accurate and numerically tractable simulation of the process. The predictions of this semi-analytical model are validated by experiments and the exact solution known for a simple thermal problem. Simulations for building a complete layer using two different scanning patterns and subsequently building of multiple layers with constant and rotating scanning patterns in successive layers are performed. The computational efficiency of the semi-analytical tool is assessed which demonstrates its potential to gain physical insight in the full SLM process with acceptable computational costs.

https://repository.tudelft.nl/islandora/object/uuid%3A37139ba4-c390-4a99-8d64-3fe7f6fee824/datastream/OBJ/download

A semi-analytical thermal modelling approach for selective laser melting

High strength steels can suffer from a loss of ductility when exposed to hydrogen, and this may lead to sudden failure. The hydrogen is either accommodated in the lattice or is trapped at defects, such as dislocations, grain boundaries and carbides. The challenge is to identify the effect of hydrogen located at different sites upon the drop in tensile strength of a high strength steel. For this purpose, literature data on the failure stress of notched and un-notched steel bars are re-analysed; the bars were tested over a wide range of strain rates and hydrogen concentrations. The local stress state at failure has been determined by the finite element (FE) method, and the concentration of both lattice and trapped hydrogen is predicted using Oriani's theory along with the stress-driven diffusion equation. The experimental data are rationalised in terms of a postulated failure locus of peak maximum principal stress versus lattice hydrogen concentration. This failure locus is treated as a unique material property for the given steel and heat treatment condition. We conclude that the presence of lattice hydrogen increases the susceptibility to hydrogen embrittlement whereas trapped hydrogen has only a negligible effect. It is also found that the observed failure strength of hydrogen charged un-notched bars is less than the peak local stress within the notched geometries. Weakest link statistics are used to account for this stressed volume effect.

http://www-mech.eng.cam.ac.uk/profiles/fleck/papers/304.pdf

A fracture criterion for the notch strength of high strength steels in the presence of hydrogen

Additive manufacturing enables the nearly uncompromised production of optimized topologies. However, due to the overhang limitation, some designs require a large number of supporting structures to enable manufacturing. Because these supports are costly to build and difficult to remove, it is desirable to find alternative designs that do not require support. In this work, a filter is presented that suppresses non-manufacturable regions within the topology optimization loop, resulting in designs that can be manufactured without the need for supports. The filter is based on front propagation, can be evaluated efficiently, and adjoint sensitivities are calculated with almost no additional computational cost. The filter can be applied also to unstructured meshes and the permissible degree of overhang can be freely chosen. The method is demonstrated on several compliance minimization problems in which its computational efficiency and flexibility are shown. The current applications are in 2D, and the proposed method is readily extensible to 3D.

/pdf/continuous-front-propagation-based-overhang-control-for-1ieohi2zsc.pdf

Can Ayas

Papers

From microstructural design to surface engineering: A tailored approach for improving fatigue life of additively manufactured meta-biomaterials.

Climb-enabled discrete dislocation plasticity

A semi-analytical thermal modelling approach for selective laser melting

A fracture criterion for the notch strength of high strength steels in the presence of hydrogen

Continuous front propagation-based overhang control for topology optimization with additive manufacturing